CN114509971B - An automatic stopping method for hydraulic ratchet wrench based on SVM oil pressure status recognition - Google Patents
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Abstract
Description
技术领域Technical field
本发明属于自动化控制技术领域,涉及液压棘轮扳手控制技术,具体涉及液压棘轮扳手判停方法。The invention belongs to the field of automation control technology, relates to hydraulic ratchet wrench control technology, and specifically relates to a hydraulic ratchet wrench judgment and stop method.
背景技术Background technique
液压棘轮扳手通过对螺栓的循环拧操作来实现对螺栓的紧固作业,液压泵站作为液压棘轮扳手的驱动装置,通过输出高冲击压力的专用液压油来为棘轮扳手提供动力。因此泵站对于扳手的控制起到关键的作用,主要包括扳手工作的启停控制、扳手的驱动力大小的控制。The hydraulic ratchet wrench tightens the bolts by cyclically tightening the bolts. The hydraulic pump station serves as the driving device of the hydraulic ratchet wrench and provides power for the ratchet wrench by outputting special hydraulic oil with high impact pressure. Therefore, the pump station plays a key role in the control of the wrench, including the start and stop control of the wrench's work and the control of the driving force of the wrench.
目前,市场上的液压泵站在驱动扳手自动化作业时多配合扭矩传感器联动工作,通过扭矩传感器来实时测量螺栓所受扭矩,以无线传输的方式将扭矩数值转化为无线信号传递给泵站控制CPU,当螺栓受到扭矩达到预设的目标扭矩大小时,泵站电磁阀闭合,液压棘轮扳手停止作业。At present, hydraulic pump stations on the market often work in conjunction with torque sensors when driving wrenches for automated operations. The torque sensors are used to measure the torque on the bolts in real time, and the torque values are converted into wireless signals through wireless transmission and transmitted to the pump station control CPU. , when the torque on the bolt reaches the preset target torque, the solenoid valve of the pump station closes and the hydraulic ratchet wrench stops working.
这种基于扭矩检测的液压扳手判停方法主要存在以下缺点:1.扭矩传感器多装备在扭矩套筒中,扭矩套筒在扳手紧固作业中不仅起到传递扭矩的作用同时他还能实时的测量螺栓所受扭矩大小,但套筒比较笨重,当操作工人需要紧固多个所处位置不同螺栓时,其也需要多次对套筒位置继续变动,比较繁琐极大的影响工作效率。2.扭矩套筒通过无线的方式将扭矩数据传递给泵站控制CPU,此过程容易受到外在环境的干扰导致传输存在延时,也受到泵站与套筒之间距离的限制,会影响泵站对扳手的自动化作业准确性。This method of judging and stopping a hydraulic wrench based on torque detection mainly has the following shortcomings: 1. The torque sensor is mostly equipped in a torque sleeve. The torque sleeve not only plays the role of transmitting torque during the wrench tightening operation, but it can also detect the torque in real time. The torque exerted on the bolts is measured, but the sleeve is relatively bulky. When the operator needs to tighten multiple bolts at different positions, he also needs to continue to change the position of the sleeve multiple times, which is cumbersome and greatly affects work efficiency. 2. The torque sleeve transmits the torque data to the pump station control CPU wirelessly. This process is easily affected by interference from the external environment, causing transmission delays. It is also limited by the distance between the pump station and the sleeve, which will affect the pump. Station-to-wrench automation accuracy.
与上述基于扭矩检测的扳手判停方法相比,公开号为CN112388552A的专利文献公开的基于油压波形相似度分析的液压扳手判停方法更具有进步性,该方法基于油压信号的分析实现对是否停止扳手作业的判断。在螺栓的紧固过程中某一次泵站加压周期扳手活塞的运动过程主要存在三个状态阶段,第一个阶段是活塞在正向行程起点保持静止(此过程克服螺栓开始转动所需的扭矩,泵站有输出但没做功,螺栓扭矩保持不变且大于扳手的输出扭矩),第二个阶段是活塞开始正行程直到活塞移动到行程终点(此过程扳手驱动轴在活塞推动下旋紧螺栓,泵站做有用功,扳手的输出扭矩与螺栓扭矩等大反向),第三个阶段是活塞在行程终点保持静止(待泵站油压加至目标值开启下次循环,泵站有输出但没做功,螺栓扭矩保持不变),该方法是控制泵站恒定输出油压的模式下工作,不能够在识别到活塞移动到行程终点时立马开启下个油压周期即活塞运动状态第三个阶段没有避免,使得泵站工作过程中还存在很多的无用功,这是导致泵站工作效率低的主要原因,且可以发现泵站所做的无用功阶段大多为高压输出阶段,对扳手的损耗较为严重不利于延长扳手的使用寿命。Compared with the above-mentioned wrench stopping method based on torque detection, the hydraulic wrench stopping method based on oil pressure waveform similarity analysis disclosed in patent document No. CN112388552A is more progressive. This method is based on the analysis of oil pressure signals to achieve Determine whether to stop wrench work. During the bolt tightening process, there are three main stages of movement of the wrench piston in a certain pumping station pressure cycle. The first stage is when the piston remains stationary at the starting point of the forward stroke (this process overcomes the torque required for the bolt to start rotating. , the pump station has output but does no work, the bolt torque remains unchanged and is greater than the output torque of the wrench), the second stage is when the piston starts the positive stroke until the piston moves to the end of the stroke (in this process, the wrench drive shaft tightens the bolt under the push of the piston , the pump station does useful work, the output torque of the wrench is in the opposite direction to the bolt torque), the third stage is when the piston remains stationary at the end of the stroke (the next cycle will be started after the oil pressure of the pump station is increased to the target value, and the pump station has output But no work is done, and the bolt torque remains unchanged). This method is to work in the mode of controlling the constant output oil pressure of the pump station. It cannot immediately start the next oil pressure cycle when it recognizes that the piston has moved to the end of the stroke, that is, the third piston movement state. This stage is not avoided, so there is still a lot of wasted work during the working process of the pumping station. This is the main reason for the low working efficiency of the pumping station. It can also be found that most of the wasted work done by the pumping station is the high-pressure output stage, which causes relatively large losses to the wrench. Seriously detrimental to extending the service life of the wrench.
液压棘轮扳手的工作过程是泵站反复加压-回油的过程,因此用液压泵站驱动液压棘轮扳手作业时,其输出油压的波形为脉冲波形,每次加压周期形成一个脉冲。The working process of a hydraulic ratchet wrench is a process of repeated pressurization and oil return by the pump station. Therefore, when the hydraulic pump station is used to drive the hydraulic ratchet wrench, the waveform of its output oil pressure is a pulse waveform, and each pressurization cycle forms a pulse.
螺栓坚固的整个过程可以分为两个阶段,第一个阶段是从开始旋转螺母到螺母开始进入紧固状态,这个阶段称为空载阶段;第二个阶段是从开始进入紧固状态到达到目标预紧力,这个阶段称为紧固阶段。The entire process of bolt strengthening can be divided into two stages. The first stage is from starting to rotate the nut to the nut starting to enter the tightening state. This stage is called the no-load stage; the second stage is from starting to enter the tightening state to reaching Target pre-tightening force, this stage is called the tightening stage.
发明内容Contents of the invention
本发明目的是针对现有通过监测扳手扭矩来判断板手是否应当停止的方式及其他扳手判停方法存在的上述不足,提供一种通过识别泵站输出油压状态来判断泵站是否应当停止驱动扳手的控制方法。The object of the present invention is to provide a method to determine whether the pump station should stop driving by identifying the output oil pressure state of the pump station in view of the above-mentioned shortcomings of the existing method of determining whether the wrench should stop by monitoring the torque of the wrench and other methods of determining whether the wrench should stop. Wrench control method.
为实现上述目的,本发明采用如下技术方案:一种基于SVM(支持向量机)油压状态识别的液压棘轮扳手自动判停方法,该方法用于判断液压泵站何时应当停止对液压棘轮扳手的驱动,包括是否开启判停的判断和是否停止扳手作业的判断;针对螺栓的空载阶段,设置液压泵站的空载工作模式,液压泵站在空载工作模式下,最大输出油压设定为扳手空载驱动油压P1,针对螺栓的紧固阶段,设置液压泵站的紧固工作模式,液压泵站在紧固工作模式下,最大输出油压设定为螺栓预紧目标油压P2,In order to achieve the above object, the present invention adopts the following technical solution: an automatic stopping method of a hydraulic ratchet wrench based on SVM (Support Vector Machine) oil pressure state recognition. This method is used to determine when the hydraulic pump station should stop operating the hydraulic ratchet wrench. The drive includes the judgment of whether to start the stop and whether to stop the wrench operation; for the no-load stage of the bolt, the no-load working mode of the hydraulic pump station is set. In the no-load working mode of the hydraulic pump station, the maximum output oil pressure is set The no-load driving oil pressure of the wrench is P1. For the tightening stage of the bolt, the tightening working mode of the hydraulic pump station is set. In the tightening working mode of the hydraulic pump station, the maximum output oil pressure is set to the bolt pre-tightening target oil pressure. P2,
是否开启判停的判断:在螺栓的空载阶段,控制泵站工作在空载工作模式下,通过SVM模型对每一个的加压周期的实时油压状态标签进行识别,当识别到油压状态标签为1时,表示螺栓进入紧固阶段,则转变泵站的工作模式为紧固工作模式,并开启是否停止驱动扳手作业的判断;是否停止驱动扳手作业的判断:在螺栓进入紧固阶段后,通过SVM模型继续对每一个的加压周期的实时油压状态标签进行识别,若识别到油压状态标签为1且一直保持到实时油压达到P2,那么实时油压达到P2时泵站停止驱动液压棘轮扳手作业。具体包括如下步骤:Determination of whether to enable judgment and stop: During the no-load stage of the bolt, the control pump station works in the no-load working mode, and the real-time oil pressure status label of each pressurization cycle is identified through the SVM model. When the oil pressure status is identified When the label is 1, it means that the bolt enters the tightening stage, then the working mode of the pump station is changed to the tightening working mode, and the judgment of whether to stop driving the wrench operation is enabled; the judgment of whether to stop driving the wrench operation: after the bolt enters the tightening stage , continue to identify the real-time oil pressure status label of each pressurization cycle through the SVM model. If the oil pressure status label is identified as 1 and remains until the real-time oil pressure reaches P2, then the pumping station will stop when the real-time oil pressure reaches P2. Drive hydraulic ratchet wrench operation. Specifically, it includes the following steps:
步骤S0:训练SVM模型;Step S0: Train the SVM model;
步骤S1:开启液压泵站驱动液压棘轮扳手作业,泵站反复执行从0开始的加压过程,同时实时监测液压泵站输出油压波形;Step S1: Start the hydraulic pump station to drive the hydraulic ratchet wrench operation. The pump station repeatedly performs the pressurization process starting from 0, and at the same time monitors the output oil pressure waveform of the hydraulic pump station in real time;
步骤S2:从第一次加压开始,轮询采集n个连续的油压数据(单次采集数据的数量可以调整,优选10个),并计算其特征值,将实时计算的特征值输入到训练好的SVM模型中进行分类,得到实时油压状态标签;Step S2: Starting from the first pressurization, collect n consecutive oil pressure data in polling (the number of single collected data can be adjusted, preferably 10), and calculate their characteristic values, and input the real-time calculated characteristic values into Classify the trained SVM model to obtain the real-time oil pressure status label;
步骤S3:若在一个加压周期中油压状态标签一直为-1则在油压达到扳手空载驱动油压P1时开启下一个加压周期;若在一个加压周期中油压达到P1前识别到油压状态标签从-1变为1,则开始执行步骤S4,此时螺栓进入紧固阶段;Step S3: If the oil pressure status label is always -1 in a pressurization cycle, start the next pressurization cycle when the oil pressure reaches the wrench no-load driving oil pressure P1; if the oil pressure reaches P1 before When it is recognized that the oil pressure status label changes from -1 to 1, step S4 begins, and the bolt enters the tightening stage;
步骤S4:在步骤S3最后一个加压周期基础上继续加压,若在油压达到P2之前油压状态标签由1变为-1,则开启下一个新的加压周期,若在在油压达到P2之前油压状态标签一直保持为1则油压达到P2时停止泵站工作;在新开启的加压周期中,若在油压达到P2之前油压状态标签由-1变1再变为-1,则开启下一个加压周期,若在油压达到P2前油压状态标签由-1变为1后一直保持为1,则在油压达到P2时停止泵站工作。Step S4: Continue to pressurize based on the last pressurization cycle of step S3. If the oil pressure status label changes from 1 to -1 before the oil pressure reaches P2, start the next new pressurization cycle. If the oil pressure is The oil pressure status label remains at 1 before reaching P2, and the pump station stops working when the oil pressure reaches P2; in the newly opened pressurization cycle, if the oil pressure status label changes from -1 to 1 before the oil pressure reaches P2, then to -1, then start the next pressurization cycle. If the oil pressure status label changes from -1 to 1 before the oil pressure reaches P2 and then remains 1, the pump station will stop working when the oil pressure reaches P2.
进一步地,在步骤S1中,使用传感器实时采集泵站输出油压数据,并将数据传递给泵站CPU。Further, in step S1, a sensor is used to collect the output oil pressure data of the pumping station in real time, and the data is transmitted to the pumping station CPU.
进一步地,步骤S2包括:Further, step S2 includes:
步骤S2-1:从第一次加压开始,泵站CPU按设定采样频率t1对实时采集的泵站输出油压数据进行采样,并对采样取得的数组(数组采用轮询赋值的方式保证数组中为最新采集的10个油压数据点)进行存储;Step S2-1: Starting from the first pressurization, the pump station CPU samples the real-time collected output oil pressure data of the pump station according to the set sampling frequency t1, and the sampled array (the array adopts polling assignment method to ensure The latest 10 oil pressure data points collected) are stored in the array;
步骤S2-2:对于实时采集到的10个油压数据点,分别计算其均值(μ)、标准差(σ)、偏度(SK)、变异系数(cv)及平均斜率(kp);Step S2-2: For the 10 oil pressure data points collected in real time, calculate their mean (μ), standard deviation (σ), skewness (SK), coefficient of variation (cv) and average slope (kp) respectively;
步骤S2-3:实时将最新的μ、σ、SK、cv、kp导入到训练好的SVM模型中进行分类,得到实时油压状态标签。Step S2-3: Import the latest μ, σ, SK, cv, kp into the trained SVM model in real time for classification, and obtain the real-time oil pressure status label.
进一步地,均值计算公式如式(1):Furthermore, the mean calculation formula is as follows (1):
(1) (1)
其中为 油压数据点, 为油压数据均值, 为数据点的个数;where is the oil pressure data point, is the mean value of the oil pressure data, and is the number of data points;
标准差计算公式如式(2):The standard deviation calculation formula is as follows (2):
(2) (2)
其中 为油压数据标准差;where is the standard deviation of oil pressure data;
偏度计算公式如式(3):The skewness calculation formula is as follows (3):
(3) (3)
其中SK为油压数据偏度;Among them, SK is the oil pressure data skewness;
变异系数计算公式如式(4):The calculation formula of the coefficient of variation is as follows: (4):
(4) (4)
其中cv为变异系数;where cv is the coefficient of variation;
平均斜率计算公式(5):Average slope calculation formula (5):
(5) (5)
其中kp为平均斜率。where kp is the average slope.
在本发明中,虽然选用了均值μ、标准差σ、偏度SK、变异系数cv、平均斜率kp5个特征值代表样本的属性,但实际上,其余可能的数据特征值在本方法中的运用也在专利保护的范围内,对于特征值选取的方法在本方法中的运用同样也在专利保护的范围内。In the present invention, although five eigenvalues of mean μ, standard deviation σ, skewness SK, coefficient of variation cv, and average slope kp are selected to represent the attributes of the sample, in fact, the remaining possible data eigenvalues are used in this method. It is also within the scope of patent protection, and the application of the feature value selection method in this method is also within the scope of patent protection.
本发明所述的液压棘轮扳手判停方法,包括对泵站的输出油压数据的实时采集和实时特征值提取,通过SVM(支持向量机)对油压状态标签的识别间接完成对螺栓是否达到预紧状态的判断从而实现对液压棘轮扳手的自动判停控制。整个方法,开始工作时由于螺栓处于很松的状态扳手首先进入空载工作阶段,该阶段泵站的输出最大油压为扳手空载驱动油压P1,在泵站0~P1循环加压周期中,如果识别的油压状态标签一直为-1,则在实时油压达到扳手空载驱动油压P1时(活塞必定完成整个正行程)开启下个加压循环;如果识别到油压状态标签由-1变为1,则说明扳手从空载阶段进入紧固阶段,由此开启是否停止扳手作业的判断。在螺栓紧固阶段,当识别到油压状态标签一直为1且实时油压达到螺栓预紧目标油压P2时扳手停止工作,当油压状态标签由-1变为1再变为-1时,说明活塞已完成正向行程且开始保持静止泵站做无用功,此时及时开启下次加压周期。通过基于SVM(支持向量机)油压状态识别的扳手判停方法,在空载阶段泵站以扳手空载驱动油压P1为目标值驱动扳手使螺栓快速进入紧固阶段,在紧固阶段通过SVM(支持向量机)模型实时识别检测油压状态标签是否存在由1变为-1这一变化(扳手活塞移动至行程终点)来自适应的开启下一次加压周期,减去了泵站在驱动液压工具紧固螺栓过程中存在的大量无用功,相较于油压波形相似度判停算法的恒定目标油压工作模式大大提高了泵站的工作效率;通过在油压状态标签一直为1过程监测实时油压是否达到目标油压从而实现扳手的准确判停。由于该算法有效的避免了加压周期油压波形中存在的无用功的高压段从而能够减少扳手在高压下的使用次数延长扳手的使用寿命;同时该方法对于螺栓预紧状态的识别仅需通过对泵站输出油压数据分析即可,避免了扳手自动化作业时必须配备扭矩传感器的条件,避免了由于扭矩数据无线传输过程存在的干扰对泵站精准判停的影响,减少了在扳手紧固作业中操作工人的工作量。The hydraulic ratchet wrench judgment method of the present invention includes real-time collection of the output oil pressure data of the pump station and real-time feature value extraction, and indirectly completes the identification of the oil pressure status label through SVM (support vector machine) to determine whether the bolt reaches the Judgment of pre-tightening status enables automatic judgment and stop control of the hydraulic ratchet wrench. In the whole method, when starting work, because the bolt is in a very loose state, the wrench first enters the no-load working stage. The maximum output oil pressure of the pump station in this stage is the wrench no-load driving oil pressure P1. During the 0~P1 cyclic pressurization cycle of the pump station , if the identified oil pressure status label is always -1, the next pressurization cycle will be started when the real-time oil pressure reaches the wrench no-load driving oil pressure P1 (the piston must complete the entire positive stroke); if the oil pressure status label is identified by -1 changes to 1, which means that the wrench enters the tightening stage from the no-load stage, thus starting the judgment of whether to stop the wrench operation. During the bolt tightening stage, when it is recognized that the oil pressure status label is always 1 and the real-time oil pressure reaches the bolt pretightening target oil pressure P2, the wrench stops working. When the oil pressure status label changes from -1 to 1 and then to -1 , indicating that the piston has completed the forward stroke and has started to remain stationary and the pump station is doing useless work. At this time, the next pressurization cycle will be started in time. Through the wrench judgment and stop method based on SVM (Support Vector Machine) oil pressure state recognition, during the no-load stage, the pump station uses the wrench no-load driving oil pressure P1 as the target value to drive the wrench so that the bolt quickly enters the tightening stage. The SVM (support vector machine) model recognizes and detects in real time whether the oil pressure status label changes from 1 to -1 (the wrench piston moves to the end of the stroke) and adaptively starts the next pressurization cycle, minus the pump station driver There is a lot of wasted work in the process of tightening bolts with hydraulic tools. Compared with the constant target oil pressure working mode of the oil pressure waveform similarity judgment and stopping algorithm, the working efficiency of the pump station is greatly improved; by monitoring the process when the oil pressure status label is always 1 Whether the real-time oil pressure reaches the target oil pressure to achieve accurate stopping of the wrench. Since this algorithm effectively avoids the useless high-pressure section in the oil pressure waveform of the pressurization cycle, it can reduce the number of times the wrench is used under high pressure and extend the service life of the wrench; at the same time, this method only needs to identify the bolt pre-tightening state by The pumping station can output oil pressure data for analysis, which avoids the requirement that a torque sensor be equipped during automated wrench operations, avoids the impact of interference on the pumping station’s accurate stopping due to interference in the wireless transmission process of torque data, and reduces the need for wrench tightening operations. workload of operators.
附图说明Description of the drawings
图1是泵站输出油压曲线与螺栓实时扭矩曲线。Figure 1 shows the output oil pressure curve of the pump station and the real-time torque curve of the bolt.
图2是扳手活塞位移曲线。Figure 2 is the wrench piston displacement curve.
图3是SVMmodel具体参数。Figure 3 shows the specific parameters of SVMmodel.
图4是实际测试泵站工作油压曲线。Figure 4 is the actual test pump station working oil pressure curve.
图5是扳手活塞位移曲线。Figure 5 is the wrench piston displacement curve.
图6是抽样样本识别结果。Figure 6 is the sampling sample identification result.
具体实施方式Detailed ways
参照图1-2,在前两个循环加压周期,螺栓处于较松的状态还未进入紧固阶段扭矩一直为0,扳手相当于空负载驱动,此过程泵站的输出油压波形较为平稳未发生明显改变,泵站不做功;Referring to Figure 1-2, in the first two pressurization cycles, the bolt is in a loose state and has not entered the tightening stage. The torque is always 0. The wrench is equivalent to no-load driving. During this process, the output oil pressure waveform of the pump station is relatively stable. No significant changes have occurred, and the pumping station does no work;
第三个周期开始螺栓进入紧固阶段,一直持续到第五个加压周期螺栓达到预紧扭矩完成紧固,第三、四个加压周期中开始加压时油压上升很快分别持续到t1、t3时刻,此过程泵站的输出油压所对应的扳手输出扭矩一直小于螺栓开始旋动的扭矩,扳手活塞在行程的起点保持静止,泵站有输出无做功;第三、四个加压周期中t1、t3时刻后泵站的输出油压上升速度明显减小,斜率明显降低分别一直持续到t2、t4时刻,此过程扳手活塞开始正行程并移动至行程终点完成对螺栓的一次拧操作,泵站做有用功;第三、四个加压周期中t2、t4时刻后泵站油压快速上升至目标油压,此过程扳手活塞在行程终点保持静止泵站有输出无做功,可以发现第三、四加压周期泵站输出油压波形呈差异明显的三段,其中第二段油压泵站做有用功;The bolts enter the tightening stage at the beginning of the third cycle and continue until the bolts reach the pre-tightening torque in the fifth pressurization cycle and the tightening is completed. When pressurization begins in the third and fourth pressurization cycles, the oil pressure rises quickly and continues until At t1 and t3, the output torque of the wrench corresponding to the output oil pressure of the pump station in this process is always smaller than the torque when the bolt starts to rotate. The wrench piston remains stationary at the starting point of the stroke, and the pump station has output but does no work; the third and fourth additions In the pressure cycle, the output oil pressure of the pump station rises significantly after moments t1 and t3, and the slope decreases significantly until moments t2 and t4 respectively. In this process, the wrench piston begins its positive stroke and moves to the end of the stroke to complete one tightening of the bolt. operation, the pump station does useful work; in the third and fourth pressurization cycles, after t2 and t4, the oil pressure of the pump station quickly rises to the target oil pressure. During this process, the wrench piston remains stationary at the end of the stroke, and the pump station has output and does no work. You can It was found that the output hydraulic pressure waveform of the pump station in the third and fourth pressurization cycles showed three distinct segments, among which the hydraulic pump station in the second segment performed useful work;
第五个加压周期紧固完成周期,活塞运动状态同前述一致先在行程起点保持静止泵站油压快速上升而后泵站油压缓慢上升活塞开始正行程,在行程某一位置处输出油压达到螺栓预紧目标油压对应扳手的输出扭矩值等于螺栓扭矩值,螺栓完成紧固。可以发现泵站在紧固阶段最后一次加压周期泵站输出油压曲线呈差异明显的两段,其中第二段做有用功。The fifth pressurization cycle is tightened to complete the cycle. The piston movement state is the same as mentioned above. It remains stationary at the starting point of the stroke and the oil pressure at the pump station rises rapidly. Then the oil pressure at the pump station rises slowly. The piston starts the positive stroke and outputs oil pressure at a certain position in the stroke. When the bolt pre-tightening target oil pressure is reached, the output torque value of the corresponding wrench is equal to the bolt torque value, and the bolt is tightened. It can be found that the output oil pressure curve of the pump station during the last pressurization cycle of the pump station in the tightening stage has two sections with obvious differences, of which the second section does useful work.
在本发明中将不同油压段的油压特征定义为一个油压状态,将螺栓紧固阶段一个加压周期的油压波形中第二段所对应的油压状态标签表示为1,将第一段及第三段所对应的油压状态,以及螺栓空载阶段的油压波形所对应的油压状态标签表示为-1。SVM(支持向量机)模型在机器学习领域中,是一个有监督的学习模型,通常用来进行模式识别、分类以及回归分析,应用到本发明中,则可通过SVM模型根据一小段油压数据的多个特征值来识别得出对应的油压状态标签,这里主要用到了SVM模型进行二分类识别,依此来设计本发明的判停算法。In the present invention, the oil pressure characteristics of different oil pressure sections are defined as one oil pressure state, and the oil pressure state label corresponding to the second segment in the oil pressure waveform of a pressurization cycle during the bolt tightening stage is expressed as 1, and the The oil pressure status corresponding to the first and third sections, and the oil pressure status label corresponding to the oil pressure waveform in the no-load stage of the bolt is expressed as -1. The SVM (Support Vector Machine) model is a supervised learning model in the field of machine learning. It is usually used for pattern recognition, classification and regression analysis. When applied to the present invention, the SVM model can be used to analyze a small piece of oil pressure data. Multiple feature values are used to identify the corresponding oil pressure status label. Here, the SVM model is mainly used for two-class recognition, and the stopping algorithm of the present invention is designed based on this.
判停算法主要为:建立SVM模型对每一次的泵站加压周期中油压状态标签进行识别,当油压状态标签一直为1且泵站实时油压达到螺栓预紧目标油压来判断螺栓已经达到预紧状态,按照此种关系来设计判停算法。The judgment and stopping algorithm is mainly: establish an SVM model to identify the oil pressure status label in each pumping station pressurization cycle. When the oil pressure status label is always 1 and the real-time oil pressure of the pumping station reaches the bolt pretightening target oil pressure, the bolt is judged. The pre-tightening state has been reached, and the stopping algorithm is designed according to this relationship.
在是否开启判停判断阶段当SVM未识别到油压状态标签为1(即油压状态标签一直为-1)且油压达到扳手空载驱动油压P1时开启下次P1加压周期;在是否停止驱动扳手作业阶段某一次加压周期中当SVM(支持向量机)模型识别到油压标签由1变为-1时开启下个加压周期;若SVM(支持向量机)模型识别到的油压标签一直为1且保持到实时油压等于螺栓预紧目标油压P2时停止泵站对扳手的驱动。In the stage of whether to start the judgment and stop judgment, when the SVM does not recognize that the oil pressure status label is 1 (that is, the oil pressure status label is always -1) and the oil pressure reaches the wrench no-load driving oil pressure P1, the next P1 pressurization cycle is started; Whether to stop driving the wrench during a certain pressurization cycle when the SVM (Support Vector Machine) model recognizes that the oil pressure label changes from 1 to -1 to start the next pressurization cycle; if the SVM (Support Vector Machine) model recognizes that the oil pressure label changes from 1 to -1, The oil pressure label is always 1 and remains until the real-time oil pressure is equal to the bolt pre-tightening target oil pressure P2 to stop the pump station from driving the wrench.
实施本发明的判停算法,具体包括如下步骤:Implementing the stopping algorithm of the present invention specifically includes the following steps:
步骤S0:SVM模型训练。Step S0: SVM model training.
步骤S0-1:多次实验得到训练测试所要用到的数据集(油压特征值和对应标签)。Step S0-1: Conduct multiple experiments to obtain the data set (oil pressure characteristic values and corresponding labels) used for training and testing.
步骤S0-2:在matlab软件中通过将多次试验得到训练数据集用于训练SVM模型,通过参数寻优算法找到最佳的c(惩罚系数)和g(RBF函数作为核函数所自带的一个参数,隐含地决定了数据映射到新的特征空间后的分布)。Step S0-2: In the matlab software, the training data set obtained from multiple experiments is used to train the SVM model, and the optimal c (penalty coefficient) and g (RBF function as the kernel function) are found through the parameter optimization algorithm. A parameter that implicitly determines the distribution of data after mapping to a new feature space).
步骤S0-3:用最佳c,g及训练数据来训练得到SVM模型参数:model结构体(结构体包含一些参数如图3所示)。Step S0-3: Use the best c, g and training data to train to obtain the SVM model parameters: model structure (the structure contains some parameters as shown in Figure 3).
步骤S1:开启液压泵站驱动液压棘轮扳手作业,泵站反复执行从0开始的加压过程,传感器实时采集泵站输出油压数据,并将数据传递给泵站控制CPU。Step S1: Start the hydraulic pump station to drive the hydraulic ratchet wrench operation. The pump station repeatedly executes the pressurization process starting from 0. The sensor collects the output oil pressure data of the pump station in real time and transmits the data to the pump station control CPU.
步骤S2:实时油压状态标签监测。Step S2: Real-time oil pressure status tag monitoring.
步骤S2-1:设置采样频率为t1,泵站CPU对实时油压数据进行采样,连续10个数据保存为一个数组。Step S2-1: Set the sampling frequency to t1, the pump station CPU samples the real-time oil pressure data, and saves 10 consecutive data as an array.
步骤S2-2:对数组中的数据进行求平均值、标准差、偏度、变异系数及平均斜率。Step S2-2: Calculate the mean, standard deviation, skewness, coefficient of variation and average slope of the data in the array.
步骤S2-3:将计算获得的平均值、标准差、偏度、变异系数及平均斜率导入SVM模型中进行分类,得到实时油压状态标签;Step S2-3: Import the calculated average value, standard deviation, skewness, coefficient of variation and average slope into the SVM model for classification, and obtain the real-time oil pressure status label;
步骤S3:是否开启判停的判断Step S3: Determine whether to enable judgment and stop
若在一个加压周期中油压状态标签一直为-1则在油压达到P1时开启下一个加压周期,若在一个加压周期中油压达到P1前识别到油压状态从-1变为1,则继续加压并开启是否停止驱动扳手作业的判断;If the oil pressure status label is always -1 in a pressurization cycle, the next pressurization cycle will be started when the oil pressure reaches P1. If it is recognized that the oil pressure status changes from -1 before the oil pressure reaches P1 in a pressurization cycle. If it is 1, then continue to pressurize and start the judgment of whether to stop driving the wrench operation;
步骤S4:是否停止驱动扳手作业的判断Step S4: Determine whether to stop driving the wrench operation
在加压周期中若油压达到P2之前油压状态标签由1变为-1,则开启下一个加压周期,若在一个加压周期中油压达到螺栓预紧目标油压P2前分类结果一直保持为1则油压达到P2时停止泵站工作。During the pressurization cycle, if the oil pressure status label changes from 1 to -1 before the oil pressure reaches P2, the next pressurization cycle will be started. If the oil pressure reaches the bolt pretightening target oil pressure P2 during a pressurization cycle, the classification result will be If it remains at 1, the pump station will stop working when the oil pressure reaches P2.
步骤S0-1中,以型号2XLCT-5的液压扳手,三级流量扳手泵,M30螺栓为例。在多个目标油压下进行多次实验(每一次实验均在泵站恒定目标油压的工作模式下循环加压,工作到螺栓拧不动为止),取每一次完整紧固作业中的所有油压数据,根据加压周期中油压斜率突变的数据点(油压拐点)将油压分段,并对每段的油压数据进行多个特征值的计算并根据该油压段对应的扳手活塞所处阶段对该组特征数据赋予标签。得到训练数据集如下表所示:In step S0-1, take the model 2XLCT-5 hydraulic wrench, three-stage flow wrench pump, and M30 bolt as an example. Conduct multiple experiments under multiple target oil pressures (each experiment is cyclically pressurized in the working mode of a constant target oil pressure in the pump station, and work until the bolts cannot be tightened). Take all the data from each complete tightening operation. For oil pressure data, the oil pressure is segmented according to the data points where the oil pressure slope suddenly changes during the pressurization cycle (oil pressure inflection point), and multiple characteristic values are calculated for the oil pressure data of each segment and based on the corresponding characteristics of the oil pressure segment. The stage at which the wrench piston is located assigns a label to this set of feature data. The training data set is obtained as shown in the following table:
其中,特征值及标签均作为SVM模型的输入,一组特征值和对应标签为一个样本训练数据此处样本数为36。(对应不同的工况在使用该算法实现扳手判停控制前最好分别对模型进行训练,不同的工况对于螺栓紧固过程的难易程度影响因素有很多)。Among them, the feature values and labels are used as the input of the SVM model, and a set of feature values and corresponding labels is a sample training data. The number of samples here is 36. (It is best to train the models separately for different working conditions before using this algorithm to implement wrench judgment and stop control. Different working conditions have many factors that affect the difficulty of the bolt tightening process).
步骤S0-2中,在matlab软件中导入数据集,并将数据集的顺序打乱,取前30组数据作为训练集,后6组数据作为测试集,利用训练集数据对c,g参数进行寻优对模型进行训练,利用测试集对训练好的模型进行实验验证。通过交叉验证寻优算法,寻找对最优c,g参数,即给定c,g在 - 之间任意值,将训练数据集划分为5等分,其中一份用来作为测试集,四份用来作为训练集,得出一个分类准确率,取得到分类准确率最高情况下的c,g作为最优参数,c为4,g为0.4353。In step S0-2, import the data set into the matlab software, shuffle the order of the data set, take the first 30 sets of data as the training set, and the last 6 sets of data as the test set, and use the training set data to test the c and g parameters. Search for optimization to train the model, and use the test set to conduct experimental verification of the trained model. Through the cross-validation optimization algorithm, find the optimal c and g parameters, that is, given any value of c and g between -, divide the training data set into 5 equal parts, one part is used as the test set, and four parts It is used as a training set to obtain a classification accuracy, and c and g are used as the optimal parameters when the classification accuracy is the highest. c is 4 and g is 0.4353.
步骤S0-3中,利用已有的c,g参数和训练集对SVM模型进行训练,得出SVM模型model结构体,其中具体参数如图3所示,其最终的决策树函数如式(6):In step S0-3, the existing c, g parameters and training set are used to train the SVM model, and the SVM model model structure is obtained. The specific parameters are shown in Figure 3, and the final decision tree function is as shown in Equation (6 ):
(6) (6)
其中b为-model.rho;n代表支持向量的个数即model.totalSV;对于每一个i,wi为model.sv_coef(i)支持向量系数,xi为model.SVs(i,:)支持向量,x为待预测标签样本,gamma就是-g参数,最后利用SVM模型对测试集数据进行预测,通过将预测结果与已知标签进行比对得出准确率为100%,可验证模型准确。Where b is -model.rho; n represents the number of support vectors, which is model.totalSV; for each i, wi is the model.sv_coef(i) support vector coefficient, xi is the model.SVs(i,:) support vector, x is the label sample to be predicted, and gamma is the -g parameter. Finally, the SVM model is used to predict the test set data. By comparing the prediction results with the known labels, the accuracy rate is 100%, which can verify that the model is accurate.
步骤S1中,在泵站出油口安装一高压传感器,由泵站控制盒为其供电,泵站上电后,传感器处于开启状态,实时测量泵站出油口油压。In step S1, a high-voltage sensor is installed at the oil outlet of the pump station, and is powered by the pump station control box. After the pump station is powered on, the sensor is on and measures the oil pressure at the oil outlet of the pump station in real time.
步骤S2中,设置CPU采样频率为6ms,在泵站每一次加压的过程中,对传感器实时传输的数据进行间隔6ms采样。为了保证数据的准确性采用平均滤波算法,每3个点取一次均值保存于数组中,创建一个10容量的数组用于存储最新采集到的油压数据点。对实时得到的10容量的数组进行特征值提取,并将特征值作为模型的输入进行实时分类得出油压的状态标签。In step S2, the CPU sampling frequency is set to 6ms. During each pressurization process of the pump station, the data transmitted in real time by the sensor is sampled at 6ms intervals. In order to ensure the accuracy of the data, an average filtering algorithm is used, and the average value of every 3 points is taken and saved in the array. An array with a capacity of 10 is created to store the latest collected oil pressure data points. Extract the eigenvalues of the 10-capacity array obtained in real time, and use the eigenvalues as the input of the model for real-time classification to obtain the oil pressure status label.
步骤S3,S4中,对油压状态标签实时监控,若实时油压达到扳手空载驱动油压P1前油压状态标签一直为-1,在油压达到扳手空载驱动油压P1时开启下一次P1加压循环;若实时油压达到P1前,油压状态标签变为1说明螺栓开始旋紧,开启是否停止扳手作业的判断,在实时油压达到螺栓预紧目标油压P2前若油压状态标签一直为1那么在油压达到P2时螺栓紧固完成可停止扳手作业,若由1变为-1则可开启下一次加压循环。扳手空载驱动油压P1是用来快速完成扳手空转过程的,很小的压力,油压大小以能够克服扳手自身的阻尼为条件;螺栓预紧目标油压P2为螺栓达到目标扭矩所需的泵站输出油压。In steps S3 and S4, the oil pressure status label is monitored in real time. If the real-time oil pressure reaches the wrench no-load driving oil pressure P1, the oil pressure status label is always -1. When the oil pressure reaches the wrench no-load driving oil pressure P1, the oil pressure status label is turned on. One P1 pressurization cycle; if the oil pressure status label changes to 1 before the real-time oil pressure reaches P1, it means the bolt starts to be tightened, and the judgment of whether to stop the wrench operation is enabled. If the oil pressure reaches the bolt pre-tightening target oil pressure P2 before the oil pressure If the pressure status label is always 1, then when the oil pressure reaches P2, the bolt tightening can be completed and the wrench operation can be stopped. If it changes from 1 to -1, the next pressurization cycle can be started. The no-load driving oil pressure P1 of the wrench is used to quickly complete the idling process of the wrench. It is a very small pressure and the oil pressure is conditioned to overcome the damping of the wrench itself; the bolt pre-tightening target oil pressure P2 is required for the bolt to reach the target torque. The pump station outputs oil pressure.
下面是本发明判停方法的一个应用实例,在该例中,棘轮扳手选用的是2XLCT-50,螺栓型号为M30,设定的液压泵输出的螺栓预紧目标油压P2为18MPa,设置CPU采样频率是6ms,扳手空载驱动油压P1为5MPa,开始启动液压泵,实时油压曲线如图4所示,对于整个紧固过程基于SVM模型的油压状态标签识别如图上方所示,第1,2两个加压周期油压在达到5MPa前油压状态标签均为-1;第3次加压周期螺栓开始紧固检测到油压状态标签为1而后变为-1(未达到预设18MPa)开启下一个加压周期;同样完成第4次加压周期,在第5次加压周期中检测到油压状态先为-1再为1且保持到18MPa,算法成功判停。为了更好的验证SVM模型抽取a~b,c~d,e~f,g~h,i~j,k~l,m~n,o~p八段数据样本(均10个数据点)进行预测,得到如图6所示分类结果,准确率为100%,模型可靠。The following is an application example of the stop judgment method of the present invention. In this example, the ratchet wrench is 2XLCT-50, the bolt model is M30, the bolt pre-tightening target oil pressure P2 output by the hydraulic pump is set to 18MPa, and the CPU is set The sampling frequency is 6ms, the no-load driving oil pressure P1 of the wrench is 5MPa, and the hydraulic pump is started. The real-time oil pressure curve is shown in Figure 4. The oil pressure status label identification based on the SVM model for the entire tightening process is shown at the top of the figure. In the first and second pressurization cycles, the oil pressure status label was -1 before the oil pressure reached 5MPa; in the third pressurization cycle, the bolts started to be tightened and the oil pressure status label was detected to be 1 and then changed to -1 (not reached). Preset 18MPa) to start the next pressurization cycle; the fourth pressurization cycle was also completed. In the fifth pressurization cycle, it was detected that the oil pressure state was first -1 and then 1 and maintained at 18MPa, and the algorithm successfully judged a stop. In order to better verify the SVM model, eight data samples (each with 10 data points) are extracted from a to b, c to d, e to f, g to h, i to j, k to l, m to n, and o to p. Prediction is made and the classification results are obtained as shown in Figure 6. The accuracy is 100% and the model is reliable.
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