CN102734528B - Method for intelligently detecting and repairing hydraulic valve chucking failure - Google Patents

Abstract

The invention relates to a method for intelligently detecting and repairing a clamping failure of a hydraulic valve, which includes the steps of transformation, installation, calibration benchmark, detection and repair. The transformation step refers to transforming the valve wall of the valve body into a special valve wall; the installation step refers to the fixed installation of multiple ultrasonic transducers on the outer surface of the valve body; the repair step refers to the central processing of the intelligent controller According to the clamping signal sent by the detection step, the device module determines the energization direction, energization number, sequence, current magnitude, energization time and Frequency, etc., according to which the corresponding solenoid coil is energized to implement clamping troubleshooting. With this technical solution, it is convenient, accurate, and real-time to predict and detect the clamping fault of the spool valve core, judge the clamping position, and conveniently use electromagnetic force to repair the clamping fault caused by pollution and radial force imbalance. The operation is simple and the effect is good.

Description

A method for intelligently detecting and repairing hydraulic valve clamping faults

technical field

The invention relates to a method related to hydraulic valve clamping faults, in particular to a method for intelligently detecting and repairing hydraulic valve clamping faults.

Background technique

The slide valve spool mechanism is the most widely used structural form in various hydraulic valves. The slide valve generally includes a valve core and a valve body, and the valve body includes a valve wall and a valve cavity. By changing the position of the spool in the valve cavity of the valve body, the slide valve can realize the change of fluid flow direction and on-off. Spool valve clamping fault is one of the most common faults and failure forms in the hydraulic system, which can be generally divided into two categories: hydraulic clamping and mechanical clamping. The hydraulic clamping is caused by radial unbalanced pressure caused by the geometrical error and coaxiality error of the spool caused by machining; while the mechanical clamping is caused by the gradual accumulation of particulate pollutants in the slide valve gap at the operating site. There are mild and severe distinctions between clamping faults.

Spool valve clamping fault is one of the most common faults and failure forms in hydraulic systems. The hydraulic system is a high-power actuator. Once a clamping failure occurs, the system will fail if it is light, and it will endanger the equipment or even personal safety if it is serious. Therefore, first of all, it is very important to find the clamping fault in time for the safe operation of the hydraulic system; secondly, the prediction of the clamping fault can kill the fault in the bud, which is of great significance to improve the reliability of the whole system; thirdly, if The clamping fault has occurred, and judging the side position of the spool clamped in the valve cavity is also critical for troubleshooting the clamping fault.

The acquisition of existing spool valve clamping information is mainly achieved through the detection of hydraulic system pressure, flow, displacement, etc., which belongs to the method of indirect detection and diagnosis, and cannot directly obtain the working state of the valve core. In particular, there are many factors that affect parameters such as pressure, flow, and displacement, and clamping is only one of them, so the accuracy of clamping detection needs to be considered.

Some scholars also proposed to use the change of the flutter signal superimposed on the valve core to detect the jamming fault. This method can realize the detection and prediction of the jamming fault to a certain extent, but because it is also indirectly detected through the change of the electromagnetic field There are many factors affecting the judgment of the mechanical movement state of the spool, and it is difficult to calibrate the judgment threshold uniformly.

In addition, there are few reports on the detection of the clamping position of the spool after clamping.

In the prior art, there are mainly two methods for troubleshooting: one is to take measures during processing and on-site operation to reduce the probability of failure. For example, install a fine filter in the system, reasonably set up a pressure equalization groove on the valve core, strictly process and assemble quality, etc.; another method is online real-time fault diagnosis and troubleshooting.

An electromagnetic reversing valve designed and manufactured by HERION has a "hammer" spool in addition to its working spool. When working normally, the "hammer" spool does not move. When the spool cannot return due to clamping, the "hammer" spool hits the working spool under the force of the spring to make it return. The limitation of this solution is that since the tapping energy is obtained by compressing the mechanical spring when the power is turned on, the "hammer" spool has only one tapping action, and it is one-way, which cannot ensure troubleshooting, nor can it be applied to Servo, proportional valve control system.

In view of this, the inventor combined his years of experience in the field of hydraulic valve research to conduct long-term research on the defects in the above-mentioned technical field, and this case came about.

Contents of the invention

The purpose of the present invention is to provide a simple structure and low cost intelligent detection and repair method of hydraulic valve clamping failure, which can conveniently, accurately and real-time forecast and detect the clamping fault of the spool valve core, judge the clamping position, and It can conveniently use electromagnetic force to repair the clamping fault caused by pollution and radial force imbalance, which is easy to operate and has good effect.

In order to achieve the above object, the technical scheme of the present invention is as follows:

A method for intelligently detecting and repairing a clamping failure of a hydraulic valve including a proportional solenoid, a valve core and a valve body with a valve cavity.

Including transformation steps, installation steps, calibration benchmark steps, detection steps and repair steps, the details are as follows:

The transformation step refers to transforming the valve wall of the valve body into a special valve wall. The special valve wall includes four main walls of the valve wall, upper, lower, left, and right, and four spacer tapes that separate the main walls of the valve wall and are arranged at the four top corners of the valve wall. And four sets of solenoid coils with magnetic frame and respectively sleeved on the main walls of the four valve walls, the valve core and the main wall of the valve wall are made of magnetic alloy, and the isolation tape is made of non-magnetic alloy; in the valve A spool magnetization device is installed between the core and the proportional electromagnet. The spool magnetization device includes a solenoid coil with a magnetic permeable frame and a cylindrical shaft core. The shaft core and the valve core are made into one. become.

Wherein the installation step refers to the fixed installation of multiple ultrasonic transducers on the outer surface of the hydraulic valve body, the axis line of the ultrasonic transducer and the central axis of the valve cavity in the valve body perpendicularly intersect; the ultrasonic transducer and The outer surface of the valve body is directly coated with an acoustic coupling medium; the multiple ultrasonic transducers are an even number of more than six, divided into two rows, and installed on the adjacent two outer surfaces of the valve body parallel to the central axis of the valve cavity in the valve body. The ultrasonic transducers on one side are arranged at equal intervals.

Among them, the calibration reference step refers to the operation of the ultrasonic detection control of the intelligent controller and the amplitude output control of the intelligent controller through the intelligent controller and the ultrasonic transducers controlled by it, so as to obtain the monitoring position of multiple ultrasonic transducers. Point the complete reference signal amplitude under normal working condition and clamping working condition.

The intelligent controller includes a central processing unit module, an electromagnetic clamping elimination module, a general proportional amplifier module, an ultrasonic clamping fault prediction, detection and positioning module, a wireless communication module, a stabilized power supply module and a magnetization control module; The detection and positioning module includes a high-speed A/D conversion module, an echo signal filtering and amplification module, an ultrasonic emission module and a multi-channel switching module.

Among them, the stabilized power supply module is connected with the central processing unit module, the electromagnetic force clamping elimination module, the general proportional amplifier module, the ultrasonic clamping fault prediction detection and positioning module, the wireless communication module, and the magnetization control module to provide the required voltage; the central processing unit The module is connected with the electromagnetic force clamping elimination module, the ultrasonic clamping fault prediction detection and positioning module, the wireless communication module, the regulated power supply module, and the magnetization control module to control the work of the entire circuit; the wireless communication module is connected with the central processing unit module; the general ratio The amplifier module is connected with the central processor module and the proportional electromagnet; the electromagnetic force clamping removal module is connected with the central processor module and four solenoid coils on the main wall of the four valve walls; the magnetization control module is connected with the central processor module and The solenoid coil on the spool magnetization device is connected; the ultrasonic clamping fault prediction, detection and positioning module is connected to the central processing unit module and multiple ultrasonic transducers, specifically, the central processing unit module is connected to the high-speed A/D conversion module to process The collected echo signal, the central processor module is connected to the ultrasonic transmitting module to control the generation of ultrasonic pulses, and the central processor module is connected to the multi-channel switching module to switch the ultrasonic transmitting and receiving objects between multiple ultrasonic transducers. The transmitting module is connected with the multi-channel switching module, the high-speed A/D conversion module is connected with the echo signal filtering and amplifying module, the echo signal filtering and amplifying module is connected with the multi-channel switching module, and the multi-channel switching module is connected with multiple ultrasonic transducers.

The intelligent controller is electrically connected with the ultrasonic transducer, proportional electromagnet, valve core magnetization device and special valve wall;

The ultrasonic detection control of the intelligent controller means that the central processing unit module first controls the multi-channel switching module to connect to a certain ultrasonic transducer according to the program, and then starts the ultrasonic transmitting module to send an electric signal and add it to the ultrasonic transducer. The ultrasonic pulse generated by the excitation of the ultrasonic transducer enters the valve wall through the acoustic coupling medium and propagates in it. At the gap between the valve wall and the valve core, due to the difference in the acoustic impedance of the hydraulic oil in the gap and the valve wall, the ultrasonic Emission is generated at the gap, and part of the reflected energy returns to the ultrasonic transducer along the original incident path, and the ultrasonic transducer converts it into an electrical pulse, and the electrical pulse signal is input to the high-speed A/ The D conversion module converts it into a digital quantity and sends it to the central processor module, and the central processor module records and saves the collected reflected wave electric pulse.

The amplitude output control of the intelligent controller refers to the central processing unit module of the intelligent controller according to the program, first the reflected wave electric pulse recorded and saved in the ultrasonic detection control of the intelligent controller is used as the signal sequence of the monitoring point , secondly, according to the hydraulic valve and ultrasonic parameters, calculate the echo position of the gap between the valve core and valve wall, and finally extract the corresponding amplitude in the signal sequence according to the position information as the signal amplitude of the monitoring point.

The detection step refers to the general working conditions of the hydraulic valve. The central processor module of the intelligent controller controls the ultrasonic clamping fault prediction, detection and positioning module to excite multiple ultrasonic transducers in turn to generate ultrasonic pulses and detect echo signals (i.e. reflected wave electric pulse), the ultrasonic clamping fault prediction detection and positioning module compares the echo signal and the reference signal amplitude to determine the clamping fault, and finally sends a fault prediction signal to the central processing unit module or sends a fault prediction signal and clamping signal, the central processor module drives the wireless communication module to send the fault prediction signal to the central control room for fault warning;

The clamping fault comparison discrimination control refers to comparing the echo signal (i.e. the reflected wave electric pulse) with the corresponding reference signal amplitude under normal working condition and clamping working condition after the amplitude-frequency analysis and processing; When the echo signal deviates from the reference signal amplitude range under normal working conditions, a fault prediction signal is sent to the central processing unit module; In addition to the fault prediction signal issued by the processor module, the clamping position in the normal direction of the plane is determined by comparing the echo signal values of more than three ultrasonic transducers on the same plane, and the position of the clamping fault is detected, and sent to the central The processor module signals a snap.

The repairing step refers to that the central processing unit module of the intelligent controller determines the direction of energization of the solenoid coil on the valve core magnetization device and the four solenoid coils on the special valve wall according to the clamping signal sent by the detection step, The number, sequence, current magnitude, energization time and frequency of energization, etc., and send the information to the spool magnetization device and the electromagnetic force clamping removal module. The spool magnetization device and the electromagnetic force clamping elimination module act accordingly to energize the corresponding solenoid coil to implement clamping troubleshooting.

Further, in the step of calibrating the reference, the operation of performing the ultrasonic detection control of the intelligent controller and the amplitude output control of the intelligent controller through the intelligent controller and the ultrasonic transducer controlled by it refers to including the steps of calibrating the normal reference and Calibrate the clamping reference step; the normal reference step refers to adjusting the hydraulic valve to the normal working condition, that is, adjusting the valve core to the coincidence of the central axis of the valve core and the valve cavity, through the ultrasonic detection control of the intelligent controller, and the intelligent control The amplitude output control of the ultrasonic transducer is used to obtain the signal amplitude as the reference signal amplitude corresponding to the normal working condition of the monitoring point where the specific ultrasonic transducer is located. Repeat the above operation, and finally obtain the normal working condition of the monitoring point where multiple ultrasonic transducers are located. The complete reference signal amplitude; the step of calibrating the clamping reference refers to adjusting the hydraulic valve to the clamping condition, through the ultrasonic detection control of the intelligent controller, and the amplitude output control of the intelligent controller, to obtain the signal amplitude as The reference signal amplitude corresponding to the clamping working condition of the monitoring point where the specific ultrasonic transducer is located, repeats the above operation, and finally obtains the complete reference signal amplitude of the clamping working condition of the monitoring points where multiple ultrasonic transducers are located.

Further, in the calibration reference step, the operations of ultrasonic detection control of the intelligent controller and amplitude output control of the intelligent controller through the intelligent controller and the ultrasonic transducer controlled by it refer to the following steps: Adjust to the normal working condition, that is, adjust the spool to coincide with the central axis of the spool and the valve cavity, through the ultrasonic detection control of the intelligent controller, and the amplitude output control of the intelligent controller, the signal amplitude is obtained as a specific ultrasonic transducer The reference signal amplitude corresponding to the normal working condition of the monitoring point; adjust the hydraulic valve to the clamping working condition, through the ultrasonic detection control of the intelligent controller, and the amplitude output control of the intelligent controller, the signal amplitude is obtained as a specific ultrasonic The corresponding reference signal amplitude when the monitoring point where the transducer is located is clamped; repeat the above operations, and finally obtain the complete reference signal amplitude of the monitoring points where multiple ultrasonic transducers are located under normal and clamped conditions.

Further, the spool magnetization device and the electromagnetic force clamping elimination module act accordingly to energize the corresponding solenoid coil to implement clamping troubleshooting, which means that the spool magnetization device 60 adopts spool magnetization control to magnetize the spool It is N or S magnetic pole, and the electromagnetic force clamping exclusion module adopts the magnetization control of the valve wall to make the main walls of the four valve walls all magnetized to the same magnetic pole as the valve core, and there are differences in size between the valve core and the main walls of the four valve walls. Equal electromagnetic repulsion, so that the valve core starts to move toward the central axis of the valve cavity, and the clamping state is relieved; or, the electromagnetic force clamping exclusion module adopts the magnetization control of the valve wall to make the main walls of the four valve walls magnetized to N Or S magnetic pole, the spool magnetization device adopts the spool magnetization control to make the spool magnetized to the same magnetic pole as the main wall of the valve wall, and electromagnetic repulsion forces of different sizes are generated between the spool and the main walls of the four valve walls, so that The spool starts to move toward the central axis of the valve chamber to relieve the clamped state.

The spool magnetization control refers to energizing the solenoid coil 61 on the spool magnetization device, controlling the current direction in the solenoid coil, and magnetizing the shaft core inserted in the solenoid coil to N or S The magnetic pole, the spool 41 integral with the shaft core 62 is just magnetized as N or S magnetic pole.

The magnetization control of the valve wall means that the four solenoid coils on the main walls of the four valve walls are energized at the same time, and the currents of each coil are equal, and the direction of the current in the four solenoid coils is controlled, so that the main walls of the four valve walls The walls are magnetized as N or S poles.

Further, the spool magnetization device 60 and the electromagnetic force clamping elimination module 21 act accordingly to energize the corresponding solenoid coil to implement clamping troubleshooting, which also includes adopting intermittent cycle control. The intermittent cycle control refers to that in After the solenoid coil 61 of the spool magnetization device 60 and the solenoid coil 433 on the main walls 431 of the four valve walls are energized for a certain period of time, each solenoid coil is powered off for a certain period of time, and then continue to implement the above repair steps. Such a cycle is repeated, so that the valve core 41 vibrates greatly along the radial direction of the valve chamber 42 under the action of the electromagnetic force. Considering that the opposite sides of the spool are clamped to different degrees, the adoption of the above-mentioned technical scheme can make the large pollution particles and dirt cakes be broken and decomposed into small particles by mechanical vibration and melted into the hydraulic oil, and then disintegrated with the oil. The circulation is taken away from the slide valve mechanism to achieve the purpose of cleaning the oil and releasing the mechanical clamping fault, and finally the valve core can stay at the center axis of the valve cavity; the radial unbalanced pressure can be reduced or eliminated, so that The spool is suspended near the central axis of the valve cavity, and the friction coefficient between the inner surface of the valve body and the spool is significantly reduced, preventing the spool from being pressed against the inner wall of the valve body and making it impossible to move, achieving the purpose of releasing hydraulic clamping, and finally making the valve The core can stay at the central axis of the valve cavity.

Further, the spool magnetization device and the electromagnetic force clamping exclusion module act accordingly to energize the corresponding solenoid coil to implement clamping troubleshooting, which means that the spool magnetization device adopts spool magnetization control to magnetize the spool as N or S magnetic pole, the electromagnetic force clamping exclusion module adopts the magnetization control of the valve wall accordingly, so that the main wall of the valve wall on the side opposite to the clamping is magnetized to the magnetic pole opposite to the valve core, and the valve core and the main wall of the valve wall on the opposite side of the clamping are magnetized Electromagnetic attraction is generated between them, so that the valve core starts to move towards the central axis of the valve cavity, and the clamping state is relieved; or the electromagnetic force clamping and exclusion module adopts the magnetization control of the valve wall to magnetize the main wall of the valve wall on the opposite side of the clamping It is N or S magnetic pole, and the spool magnetization device adopts the spool magnetization control accordingly to make the spool magnetized to the opposite magnetic pole to the main wall of the valve wall on the opposite side of the clamping, between the spool and the main wall of the valve wall on the opposite side of the clamping Electromagnetic suction is generated, so that the valve core starts to move toward the central axis of the valve cavity, and the clamping state is relieved.

The magnetization control of the valve core refers to energizing the solenoid coil on the valve core magnetization device, controlling the current direction in the solenoid coil, and magnetizing the shaft core inserted in the solenoid coil into N or S magnetic poles , the spool integrated with the shaft core is also magnetized into N or S magnetic poles.

The magnetization control of the valve wall refers to that one or two sides where the valve core of the valve cavity is clamped is the clamping side, one side or two sides opposite the clamping side are the clamping opposite side, and the clamping opposite side is The solenoid coil on the main wall of the side valve wall is energized to control the direction of the current in the solenoid coil, so that the main wall of the valve wall on the side opposite to the clamping is magnetized into N or S magnetic poles.

Further, the valve core magnetization device and the electromagnetic force clamping elimination module act accordingly to energize the corresponding solenoid coil to implement clamping troubleshooting, and also includes adopting reciprocating vibration control, and the reciprocating vibration control refers to After the solenoid coil on the main wall of the valve wall on the opposite side is energized for a certain period of time, the solenoid coil is de-energized, and then the solenoid coil on the main wall of the valve wall on the clamping side is energized for the same time, so The cycle is repeated, so that the valve core vibrates greatly along the radial direction of the valve cavity under the action of electromagnetic force. Considering that the opposite sides of the spool are clamped to different degrees, the above-mentioned technical scheme can make large particles of pollution particles and dirt cakes be broken and decomposed into small particles by mechanical vibration and melted in the hydraulic oil, and then released with the oil. The liquid circulation is taken away from the slide valve mechanism to achieve the purpose of cleaning the oil and releasing the mechanical clamping failure, and finally the valve core can stay at the center axis of the valve cavity; the radial unbalanced pressure can be reduced or eliminated, thereby Make the spool return to the central axis of the valve cavity, the friction coefficient between the inner surface of the valve and the spool is significantly reduced, and the spool is prevented from being pressed against the inner wall of the valve and cannot move, so as to achieve the purpose of releasing the hydraulic clamping, and finally make the The spool can stay on the central axis of the valve cavity.

Further, in the reciprocating vibration control, the energizing current of the solenoid coil on the main wall of the valve wall on the clamping side is smaller than the energizing current of the solenoid coil on the main wall of the valve wall on the opposite side of the clamping. Thereby, the effect of releasing the clamping by the electromagnetic suction is improved.

Further, the frequency of the ultrasonic transducer is above 10MHz. This design takes into account the small gap between the valve core and the valve wall, so that the above technical effects can be achieved more economically. the

Further, the A/D converter in the high-speed A/D conversion module in the intelligent controller selects ADS5485 or an A/D chip with equivalent performance, the ultrasonic transducer selects a straight probe, and the acoustic coupling medium is engine oil. Therefore, the above-mentioned technical effect can be achieved more economically.

Further, the valve core is made of high magnetic permeability alloy 1J87, the main wall of the valve wall and the cylindrical shaft core are made of high magnetic permeability alloy 1J89, and the insulating tape is made of YG8 non-magnetic imported tungsten steel. Therefore, the repair effect of the electromagnetic force in the technical solution is further improved, and the use effect is better.

The working principle of using this technical solution to detect clamping faults is as follows (see Figure 5 for the description of the accompanying drawings):

Ultrasound is a mechanical wave with a frequency higher than 20 kHz. This mechanical wave can propagate in a material at a certain speed and direction. It will reflect when it encounters a heterogeneous interface with different acoustic impedance (such as a defect or the bottom surface of the measured object, etc.) . This reflection phenomenon can be used for ultrasonic flaw detection, the most commonly used is the pulse echo flaw detection method. During flaw detection, the voltage emitted by the pulse oscillator is applied to the ultrasonic transducer (or ultrasonic probe, which is a detection element made of piezoelectric ceramics or quartz wafers), and the ultrasonic pulse emitted by the ultrasonic transducer passes through the acoustic coupling medium ( Such as engine oil or water, etc.) enters the material and propagates in it. After encountering a defect, part of the reflected energy returns to the ultrasonic transducer along the original path, and the ultrasonic transducer converts it into an electrical pulse. According to the position and amplitude of the defect reflected wave electric pulse (compared with the reflected wave amplitude of the artificial defect in the reference test block), the position and approximate size of the defect can be determined.

The present invention learns from the above-mentioned mechanism of ultrasonic flaw detection, and utilizes the reflection phenomenon of ultrasonic waves on heterogeneous interfaces to realize the prediction, detection and positioning of valve core clamping. When the hydraulic valve shown in Figure 5 is in normal operation, the central axis of the valve core 41 and the valve cavity in the valve body 40 coincide, the electric signal sent by the ultrasonic transmitting module is added to the ultrasonic transducer 50, and then the ultrasonic pulse generated passes through the The acoustic coupling medium (engine oil) enters the valve wall and propagates in it. At the gap between the valve wall and the valve core, due to the difference in acoustic impedance between the hydraulic oil in the gap and the valve wall, ultrasonic waves are emitted at the gap. Part of the reflected energy returns to the ultrasonic transducer along the original incident path, and the ultrasonic transducer converts it into an electrical pulse. Amplitude v makes a fuzzy judgment, and then obtains the judgment information that this is a normal working condition and there is no clamping fault; and when the hydraulic valve is hydraulically clamped or mechanically clamped, the spool deviates from the central axis of the valve cavity. At this time, the gap between the spool and the valve wall becomes smaller (the stuck working condition in Figure 5), and the position of the central processing module is still t1 according to the collected reflected wave electric pulse (the boundary position of the valve wall remains unchanged), while However, the amplitude becomes v2, which is significantly reduced compared with v1 under normal working conditions, so it can be predicted that there is a tendency for clamping faults to occur; when clamping faults occur, the spool deviates far from the central axis at this time, and There is almost no gap between the valve walls (the jamming condition in Figure 5), the position of the central processing unit module is still t1 according to the collected reflected wave electric pulse, and the amplitude has changed to v3, if the value of v3 is set to tight The detection threshold of the fault can be determined by judging whether the amplitude of the reflected wave is lower than v3 to determine the occurrence of the clamping fault. Conversely, if the ultrasonic transducer in Figure 5 is installed on the opposite side, the values of v1 v2 v3 are increasing in the process of the hydraulic valve changing from normal working condition to clamping working condition, and the reflected wave can be judged Whether the amplitude is higher than v3 is used to determine whether there is a clamping fault on the opposite side.

Preferably, in order to predict, detect and locate the clamping fault more accurately, on the axial section of the valve core, at least two ultrasonic transducers are needed to determine the position where the clamping occurs on the section (at least 8 possible orientations); since the spool has a certain length in the axial direction, clamping may occur at any position in the axial direction, and at least 3 transducers on the axis can be used to detect the position of clamping in the axial direction .

The working principle of using this technical solution to repair mechanical clamping faults is as follows:

When the electro-hydraulic proportional valve has a mechanical clamping failure, the pollution particles that are close to the gap between the valve body and the valve core are retained due to the uneven surface of the valve body and the valve core to form large pollution particles, while the smaller particles are trapped between the large particles. Constitute a dynamically growing dirt cake, and the two work together to form a common pollution jam. There are two main manifestations of valve core clamping faults, either the valve core is mainly stuck on one side of the valve cavity, or the valve core is mainly stuck on certain two sides of the valve cavity (as analyzed by the above principle, the more serious two sides are generally Neighboring). We can detect and judge this through the above-mentioned device.

When it is judged that the spool is mainly stuck on one or both sides of the valve cavity, the solenoid coil of the spool magnetization device is energized to magnetize the shaft core inserted in the solenoid coil, so that the spool connected to the shaft core Magnetized as S or N pole. At the same time, the four solenoid coils on the main wall of the valve wall are energized at the same time, and the currents of each coil are equal. Controlling the direction of the current in the four solenoid coils causes the main wall of the valve wall to be magnetized to the same magnetic pole as the spool. At this time, the valve core and the main wall of the valve wall become two magnets with the same polarity, and electromagnetic repulsion is generated between them. The electromagnetic repulsion force on one or two sides close to the valve core is relatively large, while the electromagnetic repulsion force on the other sides is relatively small. When the repulsion force is greater than the mechanical clamping force, the valve core begins to move toward the central axis of the valve cavity. Exercise, the stuck state is relieved. Considering that the opposite sides of the spool are polluted and clamped to different degrees, after the spool magnetization device and the solenoid coils on the main walls of the four sides of the valve wall are energized for a certain period of time, each solenoid coil is de-energized at the same time for a certain period of time. Over time, this cycle is repeated, and the valve core vibrates greatly in the radial direction of the valve cavity under the action of electromagnetic force, so that large particles of pollution particles and dirt cakes are broken and decomposed into small particles by mechanical vibration and melted into the hydraulic oil. With the oil circulation, it is taken away from the slide valve mechanism, so as to achieve the purpose of cleaning the oil and releasing the clamping fault, and finally the valve core can stay at the central axis of the valve cavity.

Of course, the above-mentioned electromagnetic force can also be electromagnetic attraction, that is, the magnetization of the starting valve core remains unchanged, and only the solenoid coil on the main wall of the valve wall on one or both sides of the opposite side or both sides of the valve cavity is clamped. When electrified, the corresponding main wall of the valve wall is magnetized, and the direction of the current in the solenoid coil is controlled, so that the valve core and the main wall of the valve wall become two magnets with opposite polarities, and electromagnetic attraction is generated between them. When the suction force is greater than the mechanical clamping force, the valve core starts to move toward the opposite side or diagonally, and the clamping state is relieved. Considering that the opposite sides or surroundings of the spool produce different degrees of pollution and clamping, after the solenoid coil on the main wall of one or both sides of the valve wall is energized for a certain period of time, the solenoid coil is de-energized, and then Make the solenoid coil on the main wall of the valve wall on the opposite side or both sides energized for the same time (preferably, the energizing current on the latter solenoid coil is smaller than that on the former solenoid coil, thereby improving the electromagnetic attraction force The effect of releasing the clamping), so that the cycle is repeated, and the valve core vibrates greatly along the radial direction of the valve cavity under the action of the electromagnetic force, and the effect is the same as above.

The working principle of using this technical solution to repair hydraulic clamping faults is as follows:

The reason for the hydraulic clamping failure of the electro-hydraulic proportional valve is that the radial unbalanced pressure of the spool geometry and coaxiality errors caused by machining causes the spool to press against the wall of the valve body, resulting in hydraulic clamping. There are two main manifestations of valve core clamping faults, either the valve core is mainly stuck on one side of the valve cavity, or the valve core is mainly stuck on certain two sides of the valve cavity (as analyzed by the above principle, the more serious two sides are generally Neighboring). We can detect and judge this through the above-mentioned device.

When it is judged that the spool is mainly stuck on one or both sides of the valve cavity, the solenoid coil of the spool magnetization device is energized to magnetize the shaft core inserted in the solenoid coil, so that the spool connected to the shaft core Magnetized as S or N pole. At the same time, the four solenoid coils on the main wall of the valve wall are energized at the same time, and the currents of each coil are equal. Controlling the direction of the current in the four solenoid coils causes the main wall of the valve wall to be magnetized to the same magnetic pole as the spool. At this time, the valve core and the main wall of the valve wall become two magnets with the same polarity, and electromagnetic repulsion is generated between them. The electromagnetic repulsion force on one or two sides close to the valve core is relatively large, while the electromagnetic repulsion force on the other sides is relatively small. When the repulsion force is greater than the mechanical clamping force, the valve core begins to move toward the central axis of the valve cavity. Exercise, the stuck state is relieved. After the spool magnetization device and the solenoid coils on the main walls of the four sides of the valve wall are energized for a certain period of time, each solenoid coil is de-energized for a certain period of time at the same time, and the cycle is repeated. The radial vibration of the cavity greatly reduces or eliminates the radial unbalanced pressure, so that the valve core is suspended near the central axis of the valve cavity, and the friction coefficient between the valve inner surface and the valve core is significantly reduced, preventing the valve core from being compressed. It cannot move on the inner wall of the valve to achieve the purpose of releasing the hydraulic clamping, and finally the valve core can stay at the central axis of the valve cavity.

Of course, the above-mentioned electromagnetic force can also be electromagnetic attraction, that is, the magnetization of the starting valve core remains unchanged, and only the solenoid coil on the main wall of the valve wall on one or both sides of the opposite side or both sides of the valve cavity is clamped. When electrified, the corresponding main wall of the valve wall is magnetized, and the direction of the current in the solenoid coil is controlled, so that the valve core and the main wall of the valve wall become two magnets with opposite polarities, and electromagnetic attraction is generated between them. When the suction force is greater than the hydraulic clamping force, the spool starts to move toward the opposite side or diagonally, and the clamping state is relieved. After energizing the solenoid coil on the main wall of one or both valve walls for a certain period of time, de-energize the solenoid coil, and then energize the solenoid coil on the main wall of the opposite side or both valve walls At the same time (as a preference, the energizing current on the latter solenoid coil is smaller than that on the former solenoid coil, thereby improving the effect of electromagnetic attraction to release the clamping), and so on and on, the spool will be closed under the action of electromagnetic force Under the condition of large vibration along the radial direction of the valve cavity, the radial unbalanced pressure can be reduced or eliminated, thereby achieving the above-mentioned technical effect.

When a pollution clamping fault occurs, the spool will generally deviate from the central axis of the valve cavity. In order to improve the effect of electromagnetic force to release the clamping, the solenoid on the side close to the spool or on the valve wall on both sides is energized. The current is smaller. The four spacer tapes are mainly used to improve the magnetic field distribution when the solenoid is energized, and weaken the repulsion between the same magnetic poles.

Compared with the prior art, the present invention has the following advantages and effects: 1. Applying the principle of ultrasonic flaw detection to hydraulic valve clamping fault detection, the design is simple and ingenious, and can conveniently, accurately and real-time forecast and detect the clamping of the spool valve core 2. The above-mentioned detection is a non-destructive test without changing the structure of the hydraulic valve; 3. It can realize the prediction, detection and fault location of the clamping fault; 4. Direct feedback of the position information of the spool, compared The reliability of indirect detection is better; 5. The signal used as a clamping fault detection is single, with high accuracy and low interference; 6. The two-way electromagnetic suction of the electromagnet is used to make the valve core vibrate in the radial direction, thereby crushing large pollution particles 7. Use the two-way electromagnetic suction of the electromagnet to reduce or eliminate the radial unbalanced pressure, thereby reducing the friction coefficient between the inner surface of the valve and the valve core and returning the valve core to the center axis , get rid of the hydraulic clamping fault; 8, the clamping direction is radial, the present invention releases the clamping fault through radial electromagnetic force, and its effect is stronger than the clamping solution through the axial vibration mode; 9, the technical scheme Among them, the final equilibrium point that the electromagnetic force can achieve is just the normal working condition of the proportional valve, that is, the state where the central axis of the valve core and the valve cavity coincide. 10. This technical solution has the functions of fault prediction, detection and online self-exclusion, and can provide the real-time status information of the valve to the central control room through the wireless transmission module, which improves the reliability and service life of the hydraulic valve; 11. Adopting this The technical solution has the advantages of simple structure, low cost, easy operation and good use effect.

In order to further explain the technical solution of the present invention, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments.

Description of drawings

Figure 1 is a schematic diagram of the structure of an ordinary electro-hydraulic proportional valve;

Fig. 2 is the structural representation of implementing the hydraulic valve of the present invention;

Fig. 3 is a sectional view along the direction vertical to the axis of the valve core when the electromagnetic force repair is implemented in the present invention;

Fig. 4 is a schematic diagram of the installation position of the ultrasonic transducer;

Fig. 5 is a schematic diagram of the working principle of clamping fault detection in the present invention;

Fig. 6 is the modular block diagram of intelligent controller among the present invention;

Fig. 7 is a structural block diagram between the central processing unit module of the intelligent controller and the ultrasonic clamping fault prediction, detection and positioning module and the ultrasonic transducer;

Fig. 8 is a structural schematic diagram of the valve core magnetization device.

Detailed ways

The implementation of the present invention will be further described in detail below in conjunction with the accompanying drawings.

The structure of an ordinary electro-hydraulic proportional valve is shown in Figure 1, including a valve core 1' and a valve body, and the valve body includes a valve cavity 2' and a valve wall 3'. As for other parts, generally also comprise proportional amplifier 5 ', proportional electromagnet 4 '. Proportional electromagnet 4 ' also can be single, replaces with back-moving spring at the other end. The proportional electromagnet cooperates with the spool, and drives the spool through the proportional electromagnet. The moving iron core of general proportional electromagnet 4 ' bears on spool 1 '. By changing the position of the spool 1' in the valve cavity of the valve body, the proportional valve can realize the change of fluid flow direction and on-off. The foregoing is the prior art, and will not be repeated here.

As shown in Fig. 2 to Fig. 8, it is a schematic diagram of the structure and principle involved in the hydraulic valve implementing the technical solution of the present invention.

A method for intelligently detecting and repairing a clamping failure of a hydraulic valve. The hydraulic valve includes a proportional electromagnet 30, a valve core 41 and a valve body 40 with a valve cavity 42. The above is the prior art in this field and will not be repeated here.

Including transformation steps, installation steps, calibration benchmark steps, detection steps and repair steps, the details are as follows:

Wherein the transformation step refers to transforming the valve wall of the valve body into a special valve wall 43, the special valve wall 43 includes four main walls 431 of the valve wall up and down, left and right, and the main walls of the valve wall are separated and arranged at the four top corners of the valve wall. Four spacer magnetic tapes 432 and four groups of solenoid coils 433 with magnetically permeable frames and respectively sleeved on the main walls of the four valve walls, that is, solenoids with coils. The valve core and the main wall of the valve wall are made of a magnet-conducting alloy, and the spacer tape is made of a non-magnet-conducting alloy.

In this embodiment, a cross-sectional view of the hydraulic valve along the direction perpendicular to the axis of the spool is shown in FIG. 3 . 41 is the valve core, which is made of high hardness and high magnetic permeability alloy 1J89; 42 is the valve cavity; 432 is made of YG8 non-magnetic imported tungsten steel, and there are four spacers in total, which are respectively placed on the four corners of the rectangular section , and its size is shown in the figure; 431 is the main wall of the valve wall made of high hardness and high magnetic permeability alloy 1J89. A group of solenoid coils with magnetically conductive frames, that is, solenoids with coils, are respectively sleeved on the main walls 431 of the four valve walls. Therefore, the restoration effect of the electromagnetic attraction in the technical solution is further improved, and a better technical effect is achieved at a lower cost. The four spacer tapes are mainly used to improve the magnetic field distribution when the solenoid is energized, and weaken the repulsion between the same magnetic poles.

As shown in FIG. 2 and FIG. 8 , the modification step also includes installing the spool magnetization device 60 between the spool 41 and the proportional electromagnet 30 . The spool magnetization device 60 includes a solenoid coil 61 with a magnetically permeable frame (that is, a solenoid with a coil) and a cylindrical shaft core 62 . The shaft core 62 is integrated with the valve core 41 . The shaft core is made of magnetizer alloy. In this embodiment, the structure of the spool magnetization device 60 is shown in Figure 8, consisting of a solenoid coil 61 with a magnetically permeable frame and a cylindrical shaft core 62 made of high magnetic permeability alloy 1J89; the shaft core 62 and The spool 41 is made into one body, and there are many ways to make it into one body, as long as the magnetized shaft core 62 drives the spool 41 to be magnetized with the same polarity. In this embodiment, the two are connected into one body, and the axis lines coincide. That is, the shaft core can be regarded as an extension of the valve core. Therefore, the repair effect of the electromagnetic force in the technical solution is further improved, and the use effect is better.

The four spacer tapes are mainly used to improve the magnetic field distribution when the solenoid is energized, and weaken the repulsion between the same magnetic poles. The soft magnetic materials used for the shaft core and the valve core in the spool magnetization device are high-permeability alloy 1J89 and high-permeability alloy 1J87, and the magnetic permeability of 1J87 is better than that of 1J89. The magnetic field around the solenoid coil separates, enhancing the magnetization of the spool.

It should be noted that the push rod and the spool of the existing proportional electromagnet are two separate parts. After the proportional electromagnet is energized, the push rod moves the spool proportionally. In this technical solution, in the spool magnetization device, the spool and the shaft core of the spool magnetization device are integrated, and the material of the spool section has a stronger magnetic permeability, the purpose is to improve the magnetic field distribution when the spool magnetization device is energized , Strengthen the magnetization of the material of the spool. The push rod of the proportional electromagnet in this technical solution pushes the shaft core (and the valve core) of the valve core magnetization device to move under normal working conditions.

Wherein the installation step refers to the fixed installation of multiple ultrasonic transducers on the outer surface of the hydraulic valve body, the axis line of the ultrasonic transducer and the central axis of the valve cavity in the valve body perpendicularly intersect; the ultrasonic transducer and The outer surface of the valve body is directly coated with an acoustic coupling medium; the multiple ultrasonic transducers are an even number of more than six, divided into two rows, and installed on the adjacent two outer surfaces of the valve body parallel to the central axis of the valve cavity in the valve body. The ultrasonic transducers on one side are arranged at equal intervals.

In this embodiment, the ultrasonic transducer 50 is fixedly installed on the outer surface of the valve body 40 of the hydraulic valve, and the axis line of the ultrasonic transducer perpendicularly intersects with the central axis of the valve cavity 42 in the valve body. The number and specific distribution of the ultrasonic circulators can be varied. As shown in Figure 4, a plurality of ultrasonic transducers 50 are an even number of more than six, divided into two rows, and installed on the adjacent two outer sides of the valve body 40 parallel to the central axis of the valve cavity in the valve body, each side The ultrasonic transducers are arranged at equal intervals. In this embodiment, as shown in Figure 4, a total of six ultrasonic transducers are composed of central piezoelectric ceramic elements, front and rear metal cover plates, prestressed screws, electrode sheets and insulating tubes, and are installed in two rows on hydraulic valves. On the outer upper side and the outer right side of the valve body, there are three ultrasonic transducers on each side and they fall on a straight line, which is parallel to the central axis of the valve cavity in the valve body. The specific installation position of the ultrasonic transducers is On both sides and in the middle of the surface, three ultrasonic transducers are arranged at equal intervals. Therefore, it is more convenient, accurate, and real-time to forecast, detect the clamping failure of the spool valve core, and judge the clamping position, and the cost is lower and the structure is simpler.

Considering the small gap between the spool and the valve wall, the frequency of the ultrasonic transducer should be at least 10MHz. The ultrasonic transducer and the outer surface of the valve body are directly coated with an acoustic coupling medium, which is engine oil in this embodiment. On the one hand, this design considers that the gap between the valve core and the valve wall is small, so as to achieve the above-mentioned technical effects more economically, and on the other hand, it considers achieving a better ultrasonic detection effect at a lower cost, and the detection and judgment results are more accurate.

Straight probes are used for the ultrasonic transducer, and the coupling agent is engine oil; the A/D converter in the high-speed A/D conversion module uses ADS5485 or an A/D chip with the same performance.

Among them, the calibration reference step refers to the operation of the ultrasonic detection control of the intelligent controller and the amplitude output control of the intelligent controller through the intelligent controller and the ultrasonic transducers controlled by it, so as to obtain the monitoring position of multiple ultrasonic transducers. Point the complete reference signal amplitude under normal working condition and clamping working condition. There are many specific implementation methods, please refer to the specific description in the following work process for details.

In this embodiment, as shown in Figure 2, the intelligent controller 10, a plurality of ultrasonic transducers 50 and the valve core magnetization device 60, the valve body includes a special valve wall 43, the intelligent controller 10 is connected with the ultrasonic transducers, The proportional electromagnet 30, the valve core magnetization device 60 and the special valve wall 43 are electrically connected.

As shown in Figures 6 and 7, the intelligent controller 10 includes a central processing unit module 20, an electromagnetic force clamping elimination module 21, a general proportional amplifier module (RT-5001 is used in this embodiment) 22, and ultrasonic clamping fault prediction and detection Positioning module 23, wireless communication module 24, regulated power supply module 25, and magnetization control module 26; ultrasonic clamping fault prediction, detection and positioning module 23 includes high-speed A/D conversion module 232, echo signal filtering and amplification module 233, ultrasonic emission module 234 And the multiplexing module 235.

Wherein, the stabilized power supply module 25 is connected with the central processing unit module 20, the electromagnetic force clamping elimination module 21, the universal proportional amplifier module 22, the ultrasonic clamping fault prediction detection and positioning module 23, the wireless communication module 24, and the magnetization control module 26 and provides Required voltage; the central processing unit module 20 is connected with the electromagnetic force clamping elimination module 21, the ultrasonic clamping failure prediction detection and positioning module 23, the wireless communication module 24, the voltage stabilized power supply module 25, and the magnetization control module 26 to control the work of the entire circuit The wireless communication module 24 links to each other with the central processing unit module 20; The general proportional amplifier module 22 links to each other with the central processing unit module 20 and the proportional electromagnet 30; The four solenoid coils on the wall 431 are connected; the magnetization control module 26 is connected to the central processing unit module 20 and the solenoid coils on the spool magnetization device 60 .

The ultrasonic clamping fault prediction, detection and positioning module 23 is connected to the central processor module 20 and a plurality of ultrasonic transducers 50, specifically, the central processor module 20 is connected to the high-speed A/D conversion module 232 to process the collected echo signals. The processor module 20 is connected with the ultrasonic emission module 234 to control the generation of ultrasonic pulses, and the central processing module is connected with the multiplexer module 235 and can be used to switch between multiple ultrasonic transducers 50 for ultrasonic emission and receiving objects. The ultrasonic emission module 234 It is connected with the multi-channel switching module 235, the high-speed A/D conversion module 232 is connected with the echo signal filtering and amplifying module 233, the echo signal filtering and amplifying module 233 is connected with the multi-channel switching module 235, and the multi-channel switching module 235 is connected with a plurality of ultrasonic transducers Energy device 50 is connected;

The specific circuits, components and other structures of each module for realizing the above-mentioned functions belong to the prior art, so they will not be repeated here. The intelligent controller 10 is connected to the ultrasonic transducer 50 by a 2-core or 4-core aviation plug; the intelligent controller 10 is connected to the proportional electromagnet 30 by a 7-core or 12-core plug. The four solenoid coils on the intelligent controller 10 and the special valve wall 43 and the solenoid coil on the spool magnetization device 60 are connected through a 2-core aviation plug. The moving iron core of the proportional electromagnet 30 bears against the shaft core 62 of the spool magnetization device.

The ultrasonic detection control of the intelligent controller means that the central processing unit module first controls the multi-channel switching module to connect to a certain ultrasonic transducer according to the program, and then starts the ultrasonic transmitting module to send an electric signal and add it to the ultrasonic transducer. The ultrasonic pulse generated by the excitation of the ultrasonic transducer enters the valve wall through the acoustic coupling medium and propagates in it. At the gap between the valve wall and the valve core, due to the difference in the acoustic impedance of the hydraulic oil in the gap and the valve wall, the ultrasonic Emission is generated at the gap, and part of the reflected energy returns to the ultrasonic transducer along the original incident path, and the ultrasonic transducer converts it into an electrical pulse, and the electrical pulse signal is input to the high-speed A/ The D conversion module converts it into a digital quantity and sends it to the central processor module, and the central processor module records and saves the collected reflected wave electric pulse;

The amplitude output control of the intelligent controller refers to the central processing unit module of the intelligent controller according to the program, first the reflected wave electric pulse recorded and saved in the ultrasonic detection control of the intelligent controller is used as the signal sequence of the monitoring point , secondly, according to the hydraulic valve and ultrasonic parameters, calculate the echo position of the gap between the valve core and valve wall, and finally extract the corresponding amplitude in the signal sequence according to the position information as the signal amplitude of the monitoring point;

Wherein the detection step refers to the general working conditions of the hydraulic valve, the central processing unit module of the intelligent controller controls the ultrasonic clamping failure prediction detection and positioning module 23 to stimulate multiple ultrasonic transducers in turn to generate ultrasonic pulses and detect echo signals ( That is, the reflected wave electric pulse), the ultrasonic clamping fault prediction detection and positioning module 23 performs the clamping fault comparison and discrimination control on the echo signal and the reference signal amplitude, and finally sends a fault prediction signal to the central processing unit module 20 or sends out a fault prediction signal and clamping signal, the central processing unit module 20 drives the wireless communication module 24 to send the failure prediction signal to the central control room for failure warning;

The clamping fault comparison discrimination control refers to comparing the echo signal (i.e. the reflected wave electric pulse) with the corresponding reference signal amplitude under normal working condition and clamping working condition after the amplitude-frequency analysis and processing; When the reference signal amplitude range when the echo signal deviates from the normal working condition, a failure forecast signal is sent to the central processing unit module 20 (the detection here can be that the echo signal at the monitoring point where a certain ultrasonic transducer is detected deviates from the When the monitoring point is in the normal working condition of the corresponding reference signal amplitude range, the failure prediction signal will be sent out, or it can be all detected, and the echo signals of all the monitoring points where all ultrasonic transducers are located are obtained and corresponding to the normal working condition of the monitoring point. After comparing the information of the reference signal amplitude, through the fuzzy algorithm processing, the fault prediction signal is issued when the echo signal deviates from the reference signal amplitude range); the reference signal is detected when the echo signal falls in the clamping working condition Amplitude range, in addition to sending a failure prediction signal to the central processing unit module 20 (the detection here is the same as above except that the comparison object is the reference signal amplitude when the clamping condition is the case), and by comparing more than three places on the same plane The value of the echo signal of the ultrasonic transducer determines the clamping position in the normal direction of the plane, detects the position of the clamping fault, and sends a clamping signal to the central processing unit module 20 . The above-mentioned amplitude-frequency analysis processing is specifically frequency-domain analysis and amplitude analysis. These analysis techniques belong to the prior art and will not be repeated here. The above-mentioned fuzzy algorithm belongs to the prior art and will not be repeated here.

Wherein the repairing step refers to that the central processing unit module 20 of the intelligent controller determines the solenoid coil 61 on the spool magnetization device 60 and the four solenoid coils on the special valve wall 43 according to the clamping signal sent by the detection step. The energization direction, the number of energizations, the sequence, the magnitude of the current, the energization time and frequency, etc., and send the information to the spool magnetization device 60 and the electromagnetic force clamping elimination module 21. The spool magnetization device 60 and the electromagnetic force clamping removal module 21 act accordingly to energize the corresponding solenoid coils to eliminate clamping faults.

The spool magnetization device 60 and the electromagnetic force clamping elimination module 21 act accordingly to energize the corresponding solenoid coil to implement clamping troubleshooting. There are many specific implementation methods. In this embodiment, the following is introduced in detail: Several:

First, there can be two types of subdivision here: First, it means that the spool magnetization device 60 adopts spool magnetization control to magnetize the spool to N or S magnetic poles, and the electromagnetic force clamping and exclusion module adopts valve wall magnetization accordingly. The control makes the main walls of the four valve walls all magnetized to the same magnetic pole as the valve core, and electromagnetic repulsion forces of different sizes are generated between the valve core and the main walls of the four valve walls, so that the valve core starts to move towards the central axis of the valve cavity , to relieve the clamping state; 2, or refers to the electromagnetic force clamping exclusion module adopting the magnetization control of the valve wall to magnetize the main walls of the four valve walls to N or S magnetic poles, and the valve core magnetization device 60 adopts the valve core magnetization accordingly The control makes the spool magnetized to the same magnetic pole as the main wall of the valve wall, and electromagnetic repulsion forces of different sizes are generated between the spool and the main walls of the four valve walls, so that the spool starts to move toward the central axis of the valve cavity, and the jamming is relieved. tight state;

The spool magnetization control refers to energizing the solenoid coil 61 on the spool magnetization device, controlling the current direction in the solenoid coil, and magnetizing the shaft core inserted in the solenoid coil to N or S The magnetic pole, the spool 41 integrated with the shaft core 62 is just magnetized into N or S magnetic pole; the magnetization control of the valve wall refers to the simultaneous energization of the four solenoid coils on the main wall of the four valve walls, each coil current Equal, control the current direction in the four solenoid coils, so that the main walls of the four valve walls are magnetized into N or S magnetic poles.

In addition, in the above method, it may also include taking intermittent cycle control, which means that the solenoid coil 61 of the spool magnetization device 60 and the solenoid coil 433 on the main walls 431 of the four valve walls are energized. After a certain period of time, power off each solenoid coil for a certain period of time at the same time, and then continue to implement the above repair steps. This cycle is repeated, so that the valve core 41 vibrates greatly in the radial direction of the valve cavity 42 under the action of electromagnetic force. Considering that the opposite sides of the spool are clamped to different degrees, the adoption of the above-mentioned technical scheme can make the large pollution particles and dirt cakes be broken and decomposed into small particles by mechanical vibration and melted into the hydraulic oil, and then disintegrated with the oil. The circulation is taken away from the slide valve mechanism to achieve the purpose of cleaning the oil and releasing the mechanical clamping fault, and finally the valve core can stay at the center axis of the valve cavity; the radial unbalanced pressure can be reduced or eliminated, so that The spool is suspended near the central axis of the valve cavity, and the friction coefficient between the inner surface of the valve body and the spool is significantly reduced, preventing the spool from being pressed against the inner wall of the valve body and making it impossible to move, achieving the purpose of releasing hydraulic clamping, and finally making the valve The core can stay at the central axis of the valve cavity.

Second, there can be two subdivisions here: first, it means that the spool magnetization device 60 adopts the spool magnetization control to make the spool magnetize to N or S magnetic poles, and the electromagnetic force clamping and removing module adopts the valve wall magnetization accordingly. Control, so that the main wall of the valve wall on the opposite side of the clamping is magnetized to the opposite magnetic pole to the valve core, and an electromagnetic attraction is generated between the valve core and the main wall of the valve wall on the opposite side of the clamping, so that the valve core begins to move toward the central axis of the valve cavity 2, or refers to the electromagnetic force clamping exclusion module adopting valve wall magnetization control to magnetize the main wall of the valve wall on the opposite side of the clamping to N or S magnetic poles, and the valve core magnetization device 60 according to this The spool magnetization control is adopted to magnetize the spool to the opposite magnetic pole to the main wall of the valve wall on the opposite side of the clamping, and an electromagnetic attraction is generated between the spool and the main wall of the valve wall on the opposite side of the clamping, so that the spool begins to move toward the valve cavity. Movement in the direction of the central axis to relieve the clamping state;

The spool magnetization control refers to energizing the solenoid coil 61 on the spool magnetization device, controlling the current direction in the solenoid coil, and magnetizing the shaft core inserted in the solenoid coil to N or S The magnetic pole, the spool 41 integrated with the shaft core 62 is just magnetized into N or S magnetic pole; the magnetization control of the valve wall refers to that one or both sides where the spool of the valve chamber is clamped are the clamping sides, and the clamping One side or two sides opposite to the tight side is the opposite side of the clamping, and the solenoid coil on the main wall of the valve wall on the opposite side of the clamping is energized to control the direction of the current in the solenoid coil, so that the side of the clamping opposite side is energized. The main wall of the valve wall is magnetized as N or S pole.

In addition, in the above method, it may also include adopting reciprocating vibration control, and the reciprocating vibration control refers to turning off the solenoid coil after the solenoid coil on the main wall of the valve wall on the side opposite to the clamping is energized for a certain period of time. Electricity, and then the solenoid coil on the main wall of the valve wall on the clamping side is energized for the same time, and this cycle is repeated, so that the valve core vibrates greatly in the radial direction of the valve cavity under the action of electromagnetic force. Considering that the opposite sides of the spool are clamped to different degrees, the above-mentioned technical scheme can make large particles of pollution particles and dirt cakes be broken and decomposed into small particles by mechanical vibration and melted in the hydraulic oil, and then released with the oil. The liquid circulation is taken away from the slide valve mechanism to achieve the purpose of cleaning the oil and releasing the mechanical clamping failure, and finally the valve core can stay at the center axis of the valve cavity; the radial unbalanced pressure can be reduced or eliminated, thereby Make the spool return to the central axis of the valve cavity, the friction coefficient between the inner surface of the valve and the spool is significantly reduced, and the spool is prevented from being pressed against the inner wall of the valve and cannot move, so as to achieve the purpose of releasing the hydraulic clamping, and finally make the The spool can stay on the central axis of the valve cavity.

Example 1: Mechanical clamping fault prediction, detection, location and self-exclusion (one-side clamping):

In this embodiment, the wireless communication module 24 of the intelligent controller receives a given signal from the central control room and sends the signal to the central processor module 20; the central processor module 20 transmits the signal to the general proportional amplifier module 22; The proportional amplifier module 22 outputs a power control signal to the proportional electromagnet 30 through circuit processing according to the signal. At this time, the solenoid coil 61 of the magnetization device 60 is not energized, and the moving iron core of the proportional electromagnet 30 pushes the shaft core 62 and drives the valve core. 41 moves according to the given control signal to make the hydraulic valve work normally.

The ultrasonic clamping fault prediction, detection and positioning module 23 regularly generates ultrasonic pulses to excite six ultrasonic transducers in turn and detects echo signals, and compares the echo signals with reference calibration signals. The processor module 20 issues a failure prediction. The central processing unit module 20 drives the wireless communication module 24 to send the failure forecast to the central control room for failure warning. If the ultrasonic clamping fault prediction detection and positioning module 23 detects that the echo signal falls within the clamping value range, in addition to sending a fault report to the central processing unit module 20, it will also detect the occurrence position of the clamping fault—by comparing the same plane The echo values of the upper three ultrasonic transducers determine the clamping position in the normal direction of the plane, and send the information to the central processing module 20 . The central processor module 20 determines the energization direction, current, time and frequency of the solenoid coil 61 on the spool magnetization device 60 and the four solenoid coils 5, 6, 7, 8 on the special valve wall 43 according to the signal , and send the information to the spool magnetization device 60 and the electromagnetic force clamping removal module 21 . The spool magnetization device 60 and the electromagnetic force clamping removal module 21 act accordingly to energize the corresponding solenoid coils to eliminate clamping faults.

Assuming that the spool is mainly stuck on the A side of the valve cavity (the left side shown in Figure 3, that is, the sides marked 431 and 432, on which there are solenoid coils 8), then the side opposite to this side is the B side (shown in Figure 3 shown on the right with the solenoid coil 6). Then the solenoid coil 61 on the spool magnetization device 60 is energized to magnetize the shaft core 62 to N magnetic pole, and the spool 41 integrated with the shaft core 62 is also magnetized to N magnetic pole. Simultaneously four sets of (5, 6, 7, 8) solenoid coils 433 are energized, so that the main walls 431 of the four side valve walls wound by the solenoid coils 433 are all magnetized into N magnetic poles, and the valve core 41 and the four side valve walls The main wall 431 becomes two magnets with the same polarity, and electromagnetic repulsion is generated between them. When the repulsive force is greater than the mechanical clamping force, the valve core starts to move toward the central axis of the valve cavity, and the clamping state is relieved. Considering that the AB sides of the spool all produce different degrees of pollution and clamping, after the solenoid coil 61 of the magnetization device 60 and the solenoid coil 433 on the main wall 431 of the four-side valve wall are energized for a certain period of time, simultaneously make the Each solenoid coil is powered off for a certain period of time, and this cycle is repeated. Under the action of electromagnetic force, the valve core 41 vibrates greatly along the radial direction (A to B) of the valve cavity 42, so that large pollution particles and dirt cakes are mechanically It is broken and decomposed into small particles by vibration and melted into the hydraulic oil, and is taken away from the slide valve mechanism with the oil circulation, so as to achieve the purpose of cleaning the oil and releasing the clamping fault, and finally the valve core can stay in the valve cavity axis. In particular, name the ultrasonic transducers on the same plane as 50a, 50b, and 50c according to the distance from the valve core magnetization device 60 from near to far. , 50c position, the currents on the corresponding solenoid coils 5, 6, 7, 8 are ia, ib, ic, and ia<ib<ic.

Certainly above-mentioned electromagnetic force also can be electromagnetic attraction, promptly start spool 41 magnetization constant, and only make the solenoid coil 433 on the B side valve wall main wall 433 energize, make B side valve wall main wall 431 and spool 41 become Two magnets of opposite polarity create an electromagnetic attraction between them. When the suction force is greater than the mechanical clamping force, the valve core starts to move toward the B side, and the clamping state is relieved. Considering that the opposite sides of the spool produce different degrees of pollution and clamping, after the solenoid coil on the main wall of the side B valve wall is energized for a certain period of time, the solenoid coil is de-energized, and then the valve wall of the side A side is energized. The solenoid coil on the main wall is energized for the same time (as a preference, the energizing current on the solenoid coil on the A side is smaller than that on the B side solenoid coil, thereby improving the effect of electromagnetic attraction to release the clamping), so The cycle is repeated, and the valve core vibrates greatly along the radial direction of the valve cavity under the action of the electromagnetic force, and the effect is the same as above.

Example 2: Fault prediction, detection, location and self-exclusion of hydraulic clamping (clamping on one side)

In this embodiment, the wireless communication module 24 of the intelligent controller receives a given signal from the central control room and sends the signal to the central processor module 20; the central processor module 20 transmits the signal to the general proportional amplifier module 22; The proportional amplifier module 22 outputs a power control signal to the proportional electromagnet 30 through circuit processing according to the signal. At this time, the solenoid coil 61 of the magnetization device 60 is not energized, and the moving iron core of the proportional electromagnet 30 pushes the shaft core 62 and drives the valve core. 41 moves according to the given control signal to make the hydraulic valve work normally.

The ultrasonic clamping fault prediction, detection and positioning module 23 regularly generates ultrasonic pulses to excite six ultrasonic transducers in turn and detects echo signals, and compares the echo signals with reference calibration signals. The processor module 20 issues a failure prediction. The central processing unit module 20 drives the wireless communication module 24 to send the failure forecast to the central control room for failure warning. If the ultrasonic clamping fault prediction detection and positioning module 23 detects that the echo signal falls within the clamping value range, in addition to sending a fault report to the central processing unit module 20, it will also detect the occurrence position of the clamping fault—by comparing the same plane The echo values of the upper three ultrasonic transducers determine the clamping position in the normal direction of the plane, and send the information to the central processing module 20 . The central processor module 20 determines the energization direction, current, time and frequency of the solenoid coil 62 on the spool magnetization device 60 and the four solenoid coils 5, 6, 7, 8 on the special valve wall 43 according to the signal , and send the information to the spool magnetization device 60 and the electromagnetic force clamping removal module 21 . The spool magnetization device 60 and the electromagnetic force clamping removal module 21 act accordingly to energize the corresponding solenoid coils to eliminate clamping faults.

Assuming that the spool is mainly stuck on the A side of the valve cavity (the left side shown in Figure 3, that is, the sides marked 431 and 432, on which there are solenoid coils 8), then the side opposite to this side is the B side (shown in Figure 3 shown on the right with the solenoid coil 6). Then the solenoid coil 61 on the spool magnetization device 60 is energized to magnetize the shaft core 62 to N magnetic pole, and the spool 41 integrated with the shaft core 62 is also magnetized to N magnetic pole. Simultaneously four sets of (5, 6, 7, 8) solenoid coils 433 are energized, so that the main walls 431 of the four side valve walls wound by the solenoid coils 433 are all magnetized into N magnetic poles, and the valve core 41 and the four side valve walls The main wall 431 becomes two magnets with the same polarity, and electromagnetic repulsion is generated between them. When the repulsive force is greater than the force of hydraulic clamping, the valve core starts to move toward the central axis of the valve cavity, and the clamping state is relieved. After the solenoid coil 61 of the magnetizing device 60 and the solenoid coil 433 on the main wall of the four side valve walls are energized for a certain period of time, each solenoid coil is de-energized for a certain period of time, and the cycle is repeated. Under the action of force, it vibrates greatly along the radial direction (A to B) of the valve cavity 42, so that the radial unbalanced pressure can be reduced or eliminated, so that the valve core returns to the center axis of the valve cavity, and the inner surface of the valve core and the valve core The coefficient of friction between them is significantly reduced, preventing the spool from being pressed against the inner wall of the valve and making it impossible to move, achieving the purpose of releasing hydraulic clamping, and finally enabling the spool to stay on the central axis of the valve cavity. In particular, name the ultrasonic transducers on the same plane as 50a, 50b, and 50c according to the distance from the valve core magnetization device 60 from near to far. , 50c position, the currents on the corresponding solenoid coils 5, 6, 7, 8 are ia, ib, ic, and ia<ib<ic.

Certainly above-mentioned electromagnetic force also can be electromagnetic attraction, promptly start spool 41 magnetization constant, and only make B side valve wall main wall 431 energize and make spool 41 and B side valve wall main wall 431 become two magnets of opposite polarity , generating electromagnetic attraction between them. When the suction force is greater than the hydraulic clamping force, the valve core starts to move toward the B side, and the clamping state is relieved. After the solenoid coil on the main wall of the side B valve wall is energized for a certain period of time, the solenoid coil is de-energized, and then the solenoid coil on the main wall of the side A valve wall is energized for the same time (as preferred, A The energized current on the side solenoid coil is smaller than that on the B side solenoid coil, so as to improve the effect of electromagnetic suction to release the clamping), and this cycle repeats, the valve core will move along the diameter of the valve cavity under the action of electromagnetic force Vibrating to a large extent, the radial unbalanced pressure can be reduced or eliminated, so as to achieve the above-mentioned technical effect.

As mentioned above, the clamping direction is radial, and the present invention releases the clamping failure through the radial electromagnetic force, and its effect is stronger than that of the clamping solution through axial vibration; at the same time, the technical solution is simple in structure and low in cost. Inexpensive, easy to operate and good in use effect.

In the above two embodiments, the working process of each module in the ultrasonic clamping fault prediction, detection and positioning module 23 and the central processing unit module 20 performing clamping fault prediction, detection and positioning is as follows:

Wipe clean the surface of the side of the hydraulic valve where the ultrasonic transducer is installed, apply the acoustic coupling medium (engine oil in this example), and place multiple ultrasonic transducers (six in this example) along the hydraulic valve The central axis is placed equidistant from the moving average. That is to say, six ultrasonic transducers are fixedly installed on the outer surface of the hydraulic valve body, and the axis line of the ultrasonic transducer is perpendicular to the central axis of the valve cavity in the valve body, or the six ultrasonic transducers are arranged along the valve body of the hydraulic valve. The central axis of the cavity is placed equidistantly and evenly.

Next, carry out the operation of the standard calibration step, and perform the ultrasonic detection control of the intelligent controller and the amplitude output control of the intelligent controller through the intelligent controller and the ultrasonic transducers controlled by it, so as to obtain multiple ultrasonic transducers The complete reference signal amplitude of the monitoring point under normal working conditions and clamping working conditions. In this embodiment, two types are specifically introduced:

When using it for the first time, adjust the hydraulic valve to the normal working condition, that is, adjust the spool so that the central axis of the spool coincides with the valve cavity, and through the ultrasonic detection control of the intelligent controller and the amplitude output control of the intelligent controller, the The signal amplitude is used as the reference signal amplitude corresponding to the normal working condition of the monitoring point where the No. 1 ultrasonic transducer is located, and the above operation is repeated to finally obtain the complete reference signal amplitude under the normal working condition of the monitoring point where the six ultrasonic transducers are located; Adjust the hydraulic valve to the clamping condition, and through the ultrasonic detection control of the intelligent controller, and the amplitude output control of the intelligent controller, the signal amplitude is obtained as the corresponding value for the clamping condition of the monitoring point where the No. 1 ultrasonic transducer is located. Reference signal amplitude, repeat the above operations, and finally obtain the complete reference signal amplitude when the monitoring points where multiple ultrasonic transducers are located are clamped;

The above method is to calibrate all the ultrasonic transducers one by one when adjusting to the normal working condition, and then calibrate all the ultrasonic transducers one by one when adjusting to the clamping working condition. Of course, the following method can also be adopted, one by one ultrasonic transducer, each ultrasonic transducer first calibrates the normal working condition, and then calibrates the clamping working condition. details as follows:

When using the hydraulic valve for the first time, adjust the hydraulic valve to the normal working condition, that is, adjust the spool so that the central axis of the spool and the valve chamber coincide, through the ultrasonic detection control of the intelligent controller, and the amplitude output control of the intelligent controller, the The signal amplitude is used as the reference signal amplitude corresponding to the normal working condition of the monitoring point where the specific ultrasonic transducer is located; adjust the hydraulic valve to the clamping working condition, through the ultrasonic detection control of the intelligent controller, and the amplitude output of the intelligent controller Control, obtain the signal amplitude as the reference signal amplitude corresponding to the clamping working condition of the monitoring point where the specific ultrasonic transducer is located; repeat the above operation, and finally obtain the normal working condition and clamping working condition of the monitoring point where multiple ultrasonic transducers are located. The full reference signal amplitude at the time of the test.

In addition, the above-mentioned steps of standard calibration are for an unknown hydraulic valve. If a hydraulic valve of the same type or a certain batch is tested, the hydraulic valve of the same type used for the first time can be directly replicated. The reference value obtained by the valve through the two steps, but obviously: first, this measurement method does not omit the two steps, but a direct copy on the basis of the previous measurement steps; second, for a more accurate judgment, we recommend It is better to calibrate each hydraulic valve one by one, after all, there are no exactly the same hydraulic valves.

For the general working conditions of the hydraulic valve, when the clamping fault may occur (or when the clamping fault information of the hydraulic valve needs to be judged), the central processing unit module of the intelligent controller controls the ultrasonic clamping fault prediction, detection and positioning module 23 in turn Excite multiple ultrasonic transducers to generate ultrasonic pulses at regular intervals and detect echo signals (i.e. reflected electric pulses), and the ultrasonic clamping fault prediction, detection and positioning module 23 compares the amplitude of the echo signal with the reference signal to determine the clamping fault control , and finally send a failure prediction signal or a failure prediction signal and a clamping signal to the central processing unit 20, and the central processing unit 20 drives the wireless communication module 24 to send the failure prediction signal to the central control room for failure warning.

The jamming failure comparison discrimination control is as described above. The details of the comparative discriminant control are further explained below:

When the clamping fault occurs, the spool is in contact with the valve wall on one side, and the gap between the spool and the valve wall on this side almost disappears. At this time, the echo signal (that is, the reflected wave electric pulse) is analyzed by amplitude and frequency After processing, the corresponding signal can be obtained by comparing with the corresponding reference signal amplitude under normal working condition and clamping working condition;

When it is detected that the echo signal falls within the reference signal amplitude range of the clamping working condition, in addition to sending a failure prediction signal to the central processing unit module 20, the echo signal of more than three ultrasonic transducers on the same plane is compared. The numerical value determines the clamping position in the normal direction of the plane, and detects the occurrence position of the clamping fault. The working principle of the above positioning is as follows: when the clamping occurs, a part of the valve core is pressed against the valve wall, and there is almost no gap between the two; while there is a gap between the remaining part and the valve wall. In this way, during ultrasonic echo detection, the size of the gap can be obtained by analyzing the characteristics of the echo signal. The multi-head ultrasonic probe installed along the axial distribution of the valve core can obtain the clamping information of this section. If more ultrasonic probes are installed along the circumferential direction of the valve core, three-dimensional information about clamping can be obtained, and the clamping position of the valve core can also be accurately positioned in three-dimensional space.

The above descriptions are only specific embodiments of the present invention, and are not limitations to the design of this case. All equivalent changes made according to the design key of this case all fall within the scope of protection of this case.

Claims (10)

1. A method for intelligently detecting and repairing a clamping failure of a hydraulic valve. The hydraulic valve includes a proportional electromagnet, a spool and a valve body with a valve cavity, and is characterized in that it includes a transformation step, an installation step, a calibration reference step, and a detection step and repair steps, as follows: The transformation step refers to transforming the valve wall of the valve body into a special valve wall. The special valve wall includes four main walls of the valve wall, upper, lower, left, and right, and four spacer tapes that separate the main walls of the valve wall and are arranged at the four top corners of the valve wall. And four sets of solenoid coils with magnetic frame and respectively sleeved on the main walls of the four valve walls, the valve core and the main wall of the valve wall are made of magnetic alloy, and the isolation tape is made of non-magnetic alloy; in the valve A spool magnetization device is installed between the core and the proportional electromagnet. The spool magnetization device includes a solenoid coil with a magnetic permeable frame and a cylindrical shaft core. The shaft core and the valve core are made into one. become; Wherein the installation step refers to the fixed installation of multiple ultrasonic transducers on the outer surface of the hydraulic valve body, the axis line of the ultrasonic transducer and the central axis of the valve cavity in the valve body perpendicularly intersect; the ultrasonic transducer and The outer surface of the valve body is directly coated with an acoustic coupling medium; the multiple ultrasonic transducers are an even number of more than six, divided into two rows, and installed on the adjacent two outer surfaces of the valve body parallel to the central axis of the valve cavity in the valve body. The ultrasonic transducers on one side are arranged at equal intervals; Among them, the calibration reference step refers to the operation of the ultrasonic detection control of the intelligent controller and the amplitude output control of the intelligent controller through the intelligent controller and the ultrasonic transducers controlled by it, so as to obtain the monitoring position of multiple ultrasonic transducers. Complete reference signal amplitudes under normal working conditions and clamping working conditions; The intelligent controller includes a central processing unit module, an electromagnetic clamping elimination module, a general proportional amplifier module, an ultrasonic clamping fault prediction, detection and positioning module, a wireless communication module, a stabilized power supply module and a magnetization control module; The detection and positioning module includes a high-speed A/D conversion module, an echo signal filtering and amplifying module, an ultrasonic transmitting module and a multi-channel switching module; among them, a regulated power supply module and a central processing unit module, an electromagnetic force clamping and eliminating module, and a general proportional amplifier module , Ultrasonic clamping fault prediction, detection and positioning module, wireless communication module, magnetization control module are connected to provide the required voltage; the central processing unit module and electromagnetic force clamping elimination module, ultrasonic clamping fault prediction, detection and positioning module, wireless communication module, stable The piezoelectric power supply module and the magnetization control module are connected to control the operation of the entire circuit; the wireless communication module is connected to the central processing unit; the general proportional amplifier module is connected to the central processing unit and the proportional electromagnet; the electromagnetic force clamping removal module is connected to the central processing unit The module and the four solenoid coils on the main walls of the four valve walls are connected; the magnetization control module is connected with the central processing unit module and the solenoid coil on the valve core magnetization device; the ultrasonic clamping failure prediction detection and positioning module is connected with the central processing unit Connected to the transducer module and multiple ultrasonic transducers, specifically, the central processor module is connected to the high-speed A/D conversion module to process the collected echo signals, the central processor module is connected to the ultrasonic transmitting module to control the generation of ultrasonic pulses, and the central processing module The ultrasonic transmitter module is connected to the multi-channel switching module, which can be used to switch between multiple ultrasonic transducers for transmitting and receiving objects. The ultrasonic transmitting module is connected to the multi-channel switching module, and the high-speed A/D conversion module is connected to the echo signal filtering and amplifying module. , the echo signal filtering and amplifying module is connected to the multi-channel switching module, and the multi-channel switching module is connected to multiple ultrasonic transducers; The intelligent controller is electrically connected with the ultrasonic transducer, proportional electromagnet, valve core magnetization device and special valve wall; The ultrasonic detection control of the intelligent controller means that the central processing unit module first controls the multi-channel switching module to connect to a certain ultrasonic transducer according to the program, and then starts the ultrasonic transmitting module to send an electric signal and add it to the ultrasonic transducer. The ultrasonic pulse generated by the excitation of the ultrasonic transducer enters the valve wall through the acoustic coupling medium and propagates in it. At the gap between the valve wall and the valve core, due to the difference in the acoustic impedance of the hydraulic oil in the gap and the valve wall, the ultrasonic Emission is generated at the gap, and part of the reflected energy returns to the ultrasonic transducer along the original incident path, and the ultrasonic transducer converts it into an electrical pulse, and the electrical pulse signal is input to the high-speed A/ The D conversion module converts it into a digital quantity and sends it to the central processor module, and the central processor module records and saves the collected reflected wave electric pulse; The amplitude output control of the intelligent controller refers to the central processing unit module of the intelligent controller according to the program, first the reflected wave electric pulse recorded and saved in the ultrasonic detection control of the intelligent controller is used as the signal sequence of the monitoring point , secondly, according to the hydraulic valve and ultrasonic parameters, calculate the echo position of the gap between the valve core and valve wall, and finally extract the corresponding amplitude in the signal sequence according to the position information as the signal amplitude of the monitoring point; The detection step refers to the general working conditions of the hydraulic valve. The central processing module of the intelligent controller controls the ultrasonic clamping fault prediction, detection and positioning module to stimulate multiple ultrasonic transducers in turn to generate ultrasonic pulses at regular intervals and detect echo signals. The wave signal is the reflected wave electric pulse. The ultrasonic clamping fault prediction detection and positioning module compares the echo signal with the reference signal amplitude to determine the clamping fault, and finally sends a fault prediction signal to the central processing unit module or sends a fault prediction signal and Clamping signal, the central processor module drives the wireless communication module to send the fault prediction signal to the central control room for fault warning; The clamping fault comparison discrimination control refers to comparing the amplitude of the echo signal with the corresponding reference signal amplitude during the normal working condition and the clamping working condition after the amplitude-frequency analysis and processing; when it is detected that the echo signal deviates from the normal working condition When the amplitude range of the reference signal in the clamping condition is detected, a failure prediction signal is sent to the central processing unit module; when the echo signal is detected to fall within the range of the reference signal amplitude in the clamping working condition, the failure prediction signal is sent to the central processing unit module In addition, the clamping position in the normal direction of the plane is determined by comparing the echo signal values of more than three ultrasonic transducers on the same plane, and the position of the clamping fault is detected, and a clamping signal is sent to the central processing unit module ; The repairing step refers to that the central processing unit module of the intelligent controller determines the direction of energization of the solenoid coil on the valve core magnetization device and the four solenoid coils on the special valve wall according to the clamping signal sent by the detection step, The number, sequence, current magnitude, energization time and frequency of energization, and send the information to the spool magnetization device and the electromagnetic force clamping removal module; The spool magnetization device and the electromagnetic force clamping elimination module act accordingly to energize the corresponding solenoid coil to implement clamping troubleshooting. 2. A method for intelligently detecting and repairing hydraulic valve clamping faults as claimed in claim 1, characterized in that: intelligent control is carried out through the intelligent controller and the ultrasonic transducer controlled by it in the calibration reference step The operation of the ultrasonic detection control of the device and the amplitude output control of the intelligent controller refers to the steps of calibrating the normal reference and calibrating the clamping reference; the calibration of the normal reference step refers to adjusting the hydraulic valve to the normal working condition, that is, the valve The core is adjusted to coincide with the central axis of the valve core and the valve cavity. Through the ultrasonic detection control of the intelligent controller and the amplitude output control of the intelligent controller, the signal amplitude is obtained as the corresponding value under the normal working condition of the monitoring point where the specific ultrasonic transducer is located. Repeat the above operations to finally obtain the complete reference signal amplitude under the normal working conditions of the monitoring points where multiple ultrasonic transducers are located; the step of calibrating the clamping reference refers to adjusting the hydraulic valve to the clamping working condition , through the ultrasonic detection control of the intelligent controller and the amplitude output control of the intelligent controller, the signal amplitude is obtained as the reference signal amplitude corresponding to the clamping working condition of the monitoring point where the specific ultrasonic transducer is located, and the above operations are repeated, finally Obtain the complete reference signal amplitude when the monitoring points where multiple ultrasonic transducers are located are clamped. 3. A method for intelligently detecting and repairing hydraulic valve clamping faults as claimed in claim 1, characterized in that, in the calibration reference step, intelligent control is performed through an intelligent controller and an ultrasonic transducer controlled by it The operation of the ultrasonic detection control of the device and the amplitude output control of the intelligent controller refers to the following: adjust the hydraulic valve to the normal working condition, that is, adjust the valve core to the coincidence of the central axis of the valve core and the valve cavity, and through the intelligent controller Ultrasonic detection control, as well as the amplitude output control of the intelligent controller, obtain the signal amplitude as the reference signal amplitude corresponding to the normal working condition of the monitoring point where the specific ultrasonic transducer is located; adjust the hydraulic valve to the clamping working condition, through The ultrasonic detection control of the intelligent controller, as well as the amplitude output control of the intelligent controller, obtain the signal amplitude as the reference signal amplitude corresponding to the clamping working condition of the monitoring point where the specific ultrasonic transducer is located; repeat the above operations, and finally obtain multiple The complete reference signal amplitudes of the monitoring points where the ultrasonic transducers are located are under normal working conditions and clamping working conditions. 4. A method for intelligently detecting and repairing hydraulic valve clamping faults as claimed in claim 2 or 3, characterized in that: the valve core magnetization device and the electromagnetic force clamping removal module act accordingly to make the corresponding helicoid The pipe coil is energized to implement clamping troubleshooting, which means that the spool magnetization device adopts spool magnetization control to magnetize the spool to N or S magnetic poles, and the electromagnetic force clamping elimination module adopts valve wall magnetization control accordingly to make the four valve walls The main walls are all magnetized to the same magnetic pole as the valve core, and electromagnetic repulsion forces of different sizes are generated between the valve core and the main walls of the four valve walls, so that the valve core starts to move toward the central axis of the valve cavity, and the clamping state is relieved; Alternatively, the electromagnetic force clamping exclusion module adopts valve wall magnetization control to magnetize the main walls of the four valve walls to N or S magnetic poles, and the valve core magnetization device adopts valve core magnetization control to make the valve core magnetized to the main pole of the valve wall. The magnetic poles of the walls are the same, and electromagnetic repulsion forces of different sizes are generated between the valve core and the main walls of the four valve walls, so that the valve core starts to move toward the central axis of the valve cavity, and the clamping state is relieved; The spool magnetization control refers to energizing the solenoid coil (61) on the spool magnetization device, controlling the current direction in the solenoid coil, and magnetizing the shaft core inserted in the solenoid coil to N Or S magnetic pole, the spool (41) integrated with the shaft core (62) is just magnetized as N or S magnetic pole; The magnetization control of the valve wall means that the four solenoid coils on the main walls of the four valve walls are energized at the same time, and the currents of each coil are equal, and the direction of the current in the four solenoid coils is controlled, so that the main walls of the four valve walls The walls are magnetized as N or S poles. 5. A method for intelligently detecting and repairing hydraulic valve clamping faults as claimed in claim 4, characterized in that: the valve core magnetization device and the electromagnetic force clamping removal module act accordingly to make the corresponding solenoid coil Energizing to implement clamping troubleshooting also includes taking intermittent cycle control, which means that the solenoid coil of the spool magnetization device and the solenoid coil on the main walls of the four valve walls are energized, and then simultaneously make the Each solenoid coil is de-energized for the same time, and then continue to implement the above repair steps, and this cycle is repeated, so that the valve core (41) vibrates radially along the valve cavity (42) under the action of electromagnetic force. 6. A method of intelligently detecting and repairing hydraulic valve clamping faults as claimed in claim 5, characterized in that: the frequency of the ultrasonic transducer is above 10MHz; the high-speed A/D conversion in the intelligent controller The A/D converter in the module selects ADS5485 or an A/D chip with equivalent performance, the ultrasonic transducer selects a straight probe, and the acoustic coupling medium is engine oil; the valve core and the main wall of the valve wall are made of high magnetic permeability Made of alloy 1J89, the spacer tape is made of YG8 non-magnetic imported tungsten steel. 7. A method for intelligently detecting and repairing hydraulic valve clamping faults as claimed in claim 2 or 3, characterized in that: the valve core magnetization device and the electromagnetic force clamping removal module act accordingly to make the corresponding helicoid The pipe coil is energized to implement clamping troubleshooting, which means that the spool magnetization device adopts spool magnetization control to magnetize the spool to N or S magnetic poles, and the electromagnetic force clamping elimination module adopts valve wall magnetization control accordingly to make the clamping opposite The main wall of the valve wall on the side is magnetized to the opposite magnetic pole to the valve core, and an electromagnetic attraction is generated between the valve core and the main wall of the valve wall on the side opposite to the clamping, so that the valve core starts to move toward the central axis of the valve cavity, and the clamping is relieved. state; or the electromagnetic force clamping exclusion module adopts the magnetization control of the valve wall to magnetize the main wall of the valve wall on the opposite side of the clamping to N or S magnetic poles, and the magnetization device of the valve core adopts the magnetization control of the valve core to magnetize the valve core to and The opposite magnetic pole of the main wall of the valve wall on the opposite side is clamped, and electromagnetic attraction is generated between the valve core and the main wall of the valve wall on the opposite side of the clamping, so that the valve core starts to move toward the central axis of the valve cavity, and the clamping state is relieved; The magnetization control of the valve core refers to energizing the solenoid coil on the valve core magnetization device, controlling the current direction in the solenoid coil, and magnetizing the shaft core inserted in the solenoid coil into N or S magnetic poles , the valve core integrated with the shaft core is also magnetized into N or S magnetic poles; The magnetization control of the valve wall refers to that one or two sides where the valve core of the valve cavity is clamped is the clamping side, one side or two sides opposite the clamping side are the clamping opposite side, and the clamping opposite side is The solenoid coil on the main wall of the side valve wall is energized to control the direction of the current in the solenoid coil, so that the main wall of the valve wall on the side opposite to the clamping is magnetized into N or S magnetic poles. 8. A method for intelligently detecting and repairing hydraulic valve clamping faults as claimed in claim 7, characterized in that: the valve core magnetization device and the electromagnetic force clamping removal module act accordingly to make the corresponding solenoid coil The implementation of clamping troubleshooting by energizing also includes the use of reciprocating vibration control. The reciprocating vibration control refers to energizing the solenoid coil on the main wall of the valve wall on the opposite side of the clamping, and then de-energizing the solenoid coil. And subsequently make the solenoid coil on the main wall of the valve wall on the clamping side energize for the same time, so that the cycle is repeated, so that the valve core vibrates radially along the valve cavity under the action of electromagnetic force. 9. A method for intelligently detecting and repairing hydraulic valve clamping faults as claimed in claim 8, characterized in that: in the reciprocating vibration control, the energizing current of the solenoid coil on the main wall of the valve wall on the clamping side The energizing current of the solenoid coil on the main wall of the valve wall on the side opposite to the clamping is smaller. 10. A method for intelligently detecting and repairing hydraulic valve clamping faults as claimed in claim 9, characterized in that: the frequency of the ultrasonic transducer is above 10MHz; the high-speed A/D conversion in the intelligent controller The A/D converter in the module selects ADS5485 or an A/D chip with equivalent performance, the ultrasonic transducer selects a straight probe, and the acoustic coupling medium is engine oil; the valve core and the main wall of the valve wall are made of high magnetic permeability Made of alloy 1J89, the spacer tape is made of YG8 non-magnetic imported tungsten steel.

Images