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CN117733781B - Fastening control method and device not relying on angle sensor - Google Patents

Fastening control method and device not relying on angle sensor

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Publication number
CN117733781B
CN117733781B CN202311746975.4A CN202311746975A CN117733781B CN 117733781 B CN117733781 B CN 117733781B CN 202311746975 A CN202311746975 A CN 202311746975A CN 117733781 B CN117733781 B CN 117733781B
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pressure
angle
stroke
fastening
stage
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CN117733781A (en
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徐永生
徐凌超
张卫刚
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Shanghai Jiao Tong University
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Shanghai Jiao Tong University
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Abstract

The invention belongs to the technical field of bolt fastening driven by a hydraulic wrench, and particularly discloses a fastening control method and device independent of an angle sensor. Based on the characteristics of stable flow segmentation of the hydraulic spanner pump and approximately linear correlation of the hydraulic drive spanner driving piston stroke and driving rotation angle, the invention adopts the pressure sensor to acquire the fastening curve of the fastening process, judges the stroke characteristics in real time, identifies the fastening effective section, calculates the fastening angular velocity based on the angle-time data of the last effective stroke, tracks the fastening rotation angle at each operation point according to the fastening angular velocity, and realizes angle recording and related fastening control strategies only depending on the pressure data. The invention realizes torsion angle tracking without depending on an additional angle sensor, and reduces the requirement on equipment and the purchasing cost.

Description

Fastening control method and device independent of angle sensor
Technical Field
The invention relates to the technical field of bolt fastening driven by a hydraulic wrench, in particular to a fastening control method and device independent of an angle sensor.
Background
The hydraulic spanner pump is high-efficiency fastening equipment for large-scale mechanical engineering bolting, has the advantages of small volume and large output, and is widely used in the fields of petrochemical industry, building, wind power and nuclear power. For these significant projects, high quality tightening (index includes pretightening force value and uniformity) of the flange bolts is the basis for safe operation thereof. In the case where the accuracy of the fastening force is required to be high, the fastening process must track the fastening torque and the fastening torsion angle of the bolt to achieve judgment of the fastening force and the fastening state. The angle data are important parameters in the bolt fastening process, and are important judging bases for the uniformity and the fastening efficiency of the bolt fastening force control.
In the prior art, when the hydraulic fastening pump is used, a torsion angle sensor needs to be additionally arranged, and the sensor needs to be arranged at a spanner, so that the following defects exist:
1. The prior fastening process realizes angle record, and an angle sensor is required to be arranged independently, so that the structure of a spanner part becomes more complex and is easy to damage, and unstable factors of system operation are increased.
2. The existing angle sensor can only be applied to a driving shaft type hydraulic wrench, cannot be applied to a hollow hydraulic wrench, and is difficult to use in a narrow space.
3. The existing angle sensor is added with a data acquisition interface of an electric control system, improves the complexity, and reduces the operation efficiency and the anti-interference capability.
Disclosure of Invention
In order to solve the above problems, one of the purposes of the present invention is to provide a fastening control method independent of an angle sensor, which can realize torsion angle tracking of a hydraulic wrench without installing an additional angle sensor, and reduce the requirement on equipment and purchasing cost.
In order to achieve the above purpose, the invention adopts the following specific technical scheme:
a fastening control method independent of an angle sensor, comprising the steps of:
s1, acquiring pressure data of a hydraulic pump in the fastening process of a hydraulic wrench in real time to obtain a pressure-time curve;
S2, dividing a pressure-time curve of a single stroke into four stages, namely a low pressure rising stage, a fastening effective stage, a high pressure rising stage and a return pressure releasing stage, wherein the pressure-time rising rate (namely slope) of the fourth stage is a negative value, the other stages are all positive values, the increasing rate of the second stage is smaller than that of the first stage and the third stage, and the second stage is a rotating stage in which the pressure pushes the wrench to twist normally and is the fastening effective stage;
S3, after the first effective section is finished, calculating the angle-time relation of the effective section to obtain the rotation angular speed of the wrench;
s4, after entering the next effective section, the fastening angle at the moment is obtained after the fastening angle of the previous stroke is overlapped based on the rotation angular speed of the previous stroke, the pressure at the moment and the effective stroke time.
Based on the characteristics of stable flow segmentation of the hydraulic spanner pump and approximately linear correlation of the hydraulic driving spanner driving piston stroke and driving rotation angle, the invention adopts a pressure sensor to acquire a fastening curve in the fastening process, judges stroke characteristics in real time, identifies a fastening effective section (a rotating part of a bolt or a nut), calculates fastening angular velocity based on angle-time data of the last effective stroke, tracks the fastening rotation angle at each operating point accordingly, and realizes angle record and related fastening control strategy only depending on the pressure data.
Preferably, in step S2, the calculation method of dividing the raw pressure data may be implemented by self-learning and judging the curve features based on a machine learning algorithm. Such as decision trees (random forest algorithms), gradient hoists, convolutional neural networks, full convolutional neural networks (fully convolutional network), and modified networks U-net, recurrent neural networks.
Preferably, in step S2, the calculation method for dividing the raw pressure data is based on the calculation of the pressure-time increase rate characteristics of different stages, as shown in the formula (I):
Wherein P (t) is the original pressure data output by the current pump, slop is the minimum pressure rise rate of the first stage and the third stage, deltat is a small time interval selected manually, when f seg (t) is equal to 1, the pressure conversion at the moment can be considered as the effective fastening torque, and the pressure data with f seg as 1 is restored and spliced in the internal memory, so that the complete dividing result of the historical pressure data is formed, and the time dimension is changed from (0, t original) to (0, t seg).
Preferably, in step S2, the calculation method for dividing the raw pressure data needs to implement accurate division and noise removal through the following processes:
Firstly, determining a stroke state (for example, whether the stroke state is in a pressurized state or a return state according to a solenoid valve state) based on a solenoid valve pressurizing instruction of an actual control system, and filtering out an operation error by combining whether the pressure reaches a set maximum value or not;
Secondly, combining the mechanical setting of the hydraulic pump low-pressure-level large-flow pump, testing and setting the lowest pressure of an effective stroke segmentation algorithm (fastening the pump, acquiring a pressure-time curve, selecting a value which is smaller than the initial pressure of an effective section and higher than a return slope stable section as the lowest pressure), and filtering low-slope section interference during return;
thirdly, combining the numerical fluctuation range of the sensor, balancing the effective segment segmentation sensitivity and slope fluctuation error of the system, and setting a sampling time interval and a slope judgment threshold value so as to accurately segment the effective segment. The sampling time interval is too short, the slope is large, the sampling time interval is too long, the sensitivity is insufficient, and the sampling time interval can enter an invalid section after the segmentation is delayed, so that the sampling time interval and the slope judgment threshold value are selected under the condition of simultaneously meeting the segmentation sensitivity and the slope change stability through observation in the test.
Preferably, in step S4, the calculation formula of the fastening angle is shown in (II):
A(i,ti)=AS*stroke+V(i-1)*ti(II)
Wherein, A (i, t i) represents the ith stroke, the moment is the actual rotation angle position of t i, A S represents the fixed rotation angle of a single stroke and is determined by a spanner structure, stroke is the number of strokes, and V (i-1) represents the rotation angular speed of the corresponding pressure section of the last stroke and is determined by the rotation angle of the single stroke and the time of the corresponding pressure section of the last stroke.
Preferably, the hydraulic pump is a multi-stage pump (most of the hydraulic pumps are a two-stage pump and a three-stage pump), the angle calculation algorithm must sense and respond to the flow change, and should be based on the actual pressure transition points of the experimental test pump, in the stroke of each pressure transition point (each pressure transition point stroke includes a low-pressure section before the pressure transition point and a high-pressure section after the pressure transition point), the fastening angular speed of the corresponding high-pressure section needs to be corrected based on the flow relation, and the correction coefficient is the ratio of the flow of the stage pump which effectively acts in the high-pressure section to the full flow of the multi-stage pump. The reason why the angular velocity needs to be corrected is that in the multistage pump, the flow of the lower stage pump is large and low in pressure, the flow of the stage pump is not effective after the upper pressure limit is reached (this is a pressure conversion point), so that the fastened angular velocity is reduced, and therefore the total output flow of the pump is different in different pressure sections, at the moment, the running speed of the piston is changed, the angle calculation algorithm has to sense the change of the flow and respond, otherwise, the angle calculation result is seriously wrong, and the construction safety and the precision are seriously threatened. The pressure conversion points of the pumps with different specifications have differences, the pressure conversion points are needed to be obtained through fastening test experiments of the pumps, and the correction coefficient can be obtained through actual measurement after the pressure conversion points are determined besides the flow rate proportion calculation as the inflection point of the pressure-time relation curve change of the pumps.
Specifically, when the multi-stage pump is a two-stage pump, it includes a low-pressure stage pump and a high-pressure stage pump, and has a pressure transition point, and the angle calculation algorithm is as follows:
A (i, t i)=AS*stroke+V(i-1)*ti;
After the pressure transition point of the pump, a (i, t i)=AS*stroke+kV(i-1)*ti;
Wherein V (i-1) is the full flow angular speed of the previous stroke, k is the ratio of the flow of the high-pressure stage pump to the full flow, and the full flow is the sum of the flows of the low-pressure stage pump and the high-pressure stage pump of the stroke. The angular velocity of the pressure transition point back stroke is recalculated based on the transition point stroke high pressure segment rotation angle and time.
Specifically, when the multistage pump is a three-stage pump, the multistage pump comprises a low-pressure stage pump, a medium-pressure stage pump and a high-pressure stage pump, and has two pressure conversion points, and the angle calculation algorithm is as follows:
before the first pressure transition point of the pump, a (i, t i)=AS*stroke+V(i-1)*ti;
After the first pressure transition point of the pump, a (i, t i)=AS*stroke+k1V(i-1)*ti;
After the second pressure transition point of the pump, a (i, t i)=AS*stroke+k2V(i-1)*ti;
Wherein V (i-1) is the full flow angular velocity of the previous stroke, k1 is the ratio of the sum of the flows of the medium-pressure stage pump and the high-pressure stage pump to the full flow, k2 is the ratio of the flow of the high-pressure stage pump to the full flow, and the full flow is the sum of the flows of the low-pressure stage pump, the medium-pressure stage pump and the high-pressure stage pump of the stroke. The angular velocity of the pressure transition point back stroke is recalculated based on the transition point stroke high pressure segment rotation angle and time.
Another object of the present invention is to provide an apparatus for realizing the above-mentioned fastening control method independent of an angle sensor, comprising:
A hydraulic pump station;
the hydraulic wrench is connected with the hydraulic pump station through an oil pipe;
The pressure sensor is arranged on the hydraulic pump station and used for monitoring the applied oil pressure of the hydraulic pump station to the hydraulic wrench in real time;
The man-machine interaction and electric control system is used for receiving pressure data of the pressure sensor and forming a pressure-time curve, dividing an effective fastening section for the pressure-time curve of a single stroke based on an algorithm, superposing a stroke fastening angle based on a rotation angular velocity of a previous stroke and the effective stroke time, and outputting the fastening angle at the moment.
The invention has the following beneficial effects:
1. based on the structure and the working characteristics of the hydraulic pump station and the hydraulic driving spanner, the invention provides a torsion angle calculation strategy which does not depend on an additional angle sensor, simplifies the structure, improves the reliability of equipment and reduces the equipment cost.
2. Since an additional angle sensor is not required, it is also applicable to a hollow type wrench. The problem that the traditional angle sensor is installed in a driving shaft type spanner and cannot be constructed under compact structure, narrow space or long working condition of a screw rod is solved. The invention can record the fastening angle of the fastening scene and implement the angle-related fastening strategy.
3. The acquisition module and the system interface of the angle sensor are reduced, the complexity of the control system hardware is reduced, and the external interference resistance of the system is improved.
Drawings
FIG. 1 is a schematic diagram of a hydraulic wrench slide (hydraulic piston) -crank (ratchet) mechanism in an embodiment of the invention.
FIG. 2 is a schematic diagram showing pressure-time curve segmentation in an embodiment of the present invention.
The fastening device is characterized in that the fastening device does not depend on an additional rotation angle sensor in the specific embodiment of the invention, wherein a 1-hydraulic pump station, a 2-hydraulic wrench, a 3-oil pipe, a 4-pressure sensor, 5, 6-cables, a 7-network and wireless device, an 8-remote controller and a 9-man-machine interaction and electric control system are shown in the figure.
FIG. 4 is a superimposed graph of pressure split and angle calculation in example 1 of the present invention.
Fig. 5 is a diagram showing the effect of the fastening control method independent of the angle sensor in embodiment 1 of the present invention.
FIG. 6 shows the pressure-time curve and slope distribution diagram of comparative example 1 of the present invention. In the figure, the measurement points on the abscissa represent time.
FIG. 7a is a superimposed graph of pressure split and angle calculation in comparative example 1 of the present invention.
Fig. 7b is an enlarged view of a portion of fig. 7 a.
FIG. 8 is a superimposed graph of pressure split and angle calculation in comparative example 2 of the present invention.
FIGS. 9a-9c are graphs showing erroneous results due to poor pressure split and angle calculation in comparative example 3 of the present invention.
FIG. 10 is a graph showing the results of the pressure division and the angle calculation in comparative example 3 of the present invention.
Detailed Description
The invention is further described below with reference to the drawings and specific examples.
The specific implementation of the fastening control method independent of the angle sensor provided by the invention is as follows:
(1) The hydraulic fastening system mainly comprises a hydraulic pump and a hydraulic wrench, and the hydraulic pump and the hydraulic wrench are in power connection through a hydraulic oil pipe. The output pressure of the hydraulic pump is up to 70MPa, the output flow of the pump is stable, namely the volume of the oil liquid output per unit time is determined.
(2) In order to realize the fastening of the bolts, the hydraulic wrench is a reciprocating ratchet mechanism, and a hydraulic cylinder and a connecting rod in the wrench are combined into a crank-connecting rod mechanism to push the ratchet to rotate. The rotation angle of each stroke of the ratchet is fixed, and because the rotation angle range is small (generally about 20 degrees), the pushing displacement of the piston (slide) and the rotation angle of the ratchet are approximately linearly and positively correlated (generally less than 3 percent of deviation), and the schematic diagram is shown in fig. 1.
(3) The flow rate of the pump is relatively stable, namely the volume of the oil discharged in unit time is determined, and the relation of the (2) and the incompressibility of the hydraulic oil are combined, so that the rotation angle of the ratchet wheel of the wrench in unit time is the same. The angle of rotation of the wrench can thus be calculated based on the pressure-time data of the hydraulic pump.
(4) Based on the above facts, the rotation speed of the hydraulic pump is stable in the process of pushing the wrench to rotate in the effective pressure working section, and the obtained pressure-time data comprise the return stroke of the hydraulic cylinder and the invalid stage of boosting after the hydraulic cylinder reaches the mechanical limit because the wrench is in the reciprocating process, so that the collected pressure data needs to be divided in real time, namely whether the wrench rotates or not is judged.
(5) The extracted pressure-time curve is divided into four stages, ①, namely a pressure rising section which is enough to push the wrench to start a rotating section, ②, namely a rotating section which is used for pushing the wrench to twist normally, ③, namely a high pressure rising section which is the highest pressure section of the pressure limiting valve after the piston of the hydraulic cylinder reaches the mechanical limit, and ④, namely a return section of the hydraulic cylinder. Wherein the slope of the fourth phase is negative, the rest phases are positive and the slope of the second phase is smaller than the slopes of the first and third phases, only the second phase being valid. We can distinguish the obtained data features by combining them, and divide the effective segments into the effective segments by using algorithm, as shown in fig. 2, wherein the green curve is a complete pressure-time (or sampling point) curve, the red part is the identified effective segments of wrench rotation, the distinguishing algorithm comprises ① based on a regular program control method, and ② based on a machine learning algorithm (such as CNN, RNN, light GBMXGboost, etc.).
(6) After the first complete effective segment is obtained, the rotation angle is determined (for example, 24 DEG) based on the rotation angle of a single stroke, the rotation angular speed is calculated by combining the effective segment time, and real-time angle data is obtained in the subsequent stroke process based on the angular speed and the accumulated angle calculated by the previous stroke.
(7) After the angle data are obtained, the angle of the fastening process can be monitored, and advanced fastening strategies such as angle fastening control and yield limit control are realized.
(8) Based on the torsion angle calculation strategy, an angle-dependent fastening device independent of an additional rotation angle sensor is provided, as shown in fig. 3, the device comprises a hydraulic pump station 1, a hydraulic wrench 2 connected with the hydraulic pump station 1 through an oil pipe 3 and a fastening control system, wherein the fastening control system comprises a pressure sensor 4 arranged on the hydraulic pump station 1 and a man-machine interaction and electric control system 9 for receiving pressure data of the pressure sensor 4 and performing data algorithm processing. More specifically, the fastening control system further comprises a network and wireless device 7 for facilitating system operation and a remote controller 8 for performing start-stop control, the man-machine interaction and electric control system 9 is connected with the hydraulic pump station 1, the pressure sensor 4 and the remote controller 8 through cables respectively, and the network and wireless device 7 is installed in the man-machine interaction and electric control system 9.
Example 1
The following is a specific fastening control method independent of an angle sensor, which is proposed based on the foregoing implementation basis and device, and includes the following steps:
s0. the instrument is ready to work, namely the traditional mechanical pressure gauge of the hydraulic pump station 1 is replaced by a pressure transmitter, the pressure sensor 4 and the hydraulic pump station 1 are connected with a fastening control system, and an oil pipe 3 is connected between the hydraulic pump station 1 and the hydraulic wrench 2.
S1, starting the hydraulic pump station 1, and periodically collecting pressure data of the hydraulic wrench 2 during the fastening process by the fastening control system to obtain a pressure-time curve.
S2, distinguishing effective segments (second stage) of the obtained pressure-time curve based on the pressure-time characteristics, wherein the effective segment segmentation calculation steps are as follows:
a. the slope of the pressure data is calculated, and only if the slope is larger than 0 and smaller than a certain determined value, and the pressure is not higher than a certain determined P1, the effective fastening time of the spanner operation is realized.
B. based on the analysis, a calculation method for dividing the original pressure data is designed, and the basic principle is given in the formula (I):
Wherein P (t) is the original pressure data output by the current pump, slop is the minimum pressure rise rate of the first stage and the third stage, deltat is a small time interval manually selected, when f seg (t) is equal to 1, the pressure conversion at the moment can be considered as the effective fastening torque, all the pressure data with f seg as 1 are restored and spliced in a memory, thus forming the complete segmentation result of the historical pressure data, and the time dimension is changed from (0, t original) to (0, t seg);
c. The calculation method for dividing the original pressure data needs to realize accurate division and noise removal through the following processes:
firstly, judging a stroke state based on an electromagnetic valve pressurizing instruction of an actual control system, and filtering out an operation error by combining whether the pressure reaches a set maximum value or not;
Secondly, combining the mechanical setting of a low-pressure-stage large-flow pump of the hydraulic pump, testing and setting the lowest pressure of an effective stroke segmentation algorithm, and filtering low-slope section interference during return stroke (the lowest pressure in the embodiment is set to be 4 MPa);
thirdly, combining the sensor value fluctuation range, balancing the effective section segmentation sensitivity and slope fluctuation error of the system, and setting a sampling time interval and a slope judgment threshold value to accurately segment the effective section (the sampling time interval is 20ms, and the slope judgment threshold value is 60MPa/s in the embodiment).
The curve segmentation obtained after optimizing the slope control parameters according to the above procedure is shown in fig. 4.
S3, after the first effective section is finished, calculating the angle-time relation of the effective section, and obtaining the rotation angular speed of the wrench.
S4, after entering the next effective section, based on the rotation angular velocity of the previous stroke and the effective stroke time, the fastening angle of the moment is obtained after the fastening angle of the previous stroke is overlapped. Specifically, the angle calculation algorithm must sense the flow change and respond, and should use different angle calculation parameters in different pressure segments as the control quantity of the angle updating algorithm based on the actual pressure conversion point of the experimental test pump. In the embodiment, the adopted hydraulic pump is a two-stage pump, and the experimental test shows that the pressure conversion point is 7.3MPa, the angular speed of the pressure conversion stroke is reduced to 0.29 of the original low-pressure section speed, and the stroke angle updating is completed. And after the stroke is finished, updating the angular speed of the high-pressure section based on the actual rotation angle and time of the high-pressure section, and calculating the angle of the next stroke. The specific angle calculation algorithm in this embodiment is as follows (V is the full flow angular velocity):
A (i, t i)=AS*stroke+V(i-1)*ti;
after the pressure transition point of the pump, a (i, t i)=AS*stroke+0.29V(i-1)*ti.
After the angle is obtained, accurate fastening of the bolt can be implemented according to a preset fastening control strategy (such as torque control, angle monitoring, torque, angle control and yield limit control).
As shown in fig. 5, it can be seen that the angle data calculated by the algorithm according to the embodiment is substantially consistent with the experimental result (the data output from the angular sensor), and thus the method according to the embodiment has higher accuracy.
Comparative example 1
In the present comparative example, the segmentation and noise removal process was not performed as in step S2, but the parameters were set to be the lowest pressure of 0MPa, the time interval of 10ms, and the slope judgment threshold of 60MPa/S, as compared with example 1. The obtained pressure-time curve is shown in fig. 6, and it is known from the graph that the slope of each region is not completely distinguished, the angle data of the low-pressure section is largely lost (fig. 7 a), and the ineffective section of the low-pressure rising section cannot be distinguished even by the slope alone, as shown in fig. 7b, so that the algorithm of the formula (I) needs a complete processing algorithm to realize accurate segmentation and noise removal.
Comparative example 2
In the present comparative example, compared with the embodiment 1, in the step S3, different angle calculation parameters are not adopted in different pressure sections, the part takes the low pressure section speed as the whole angular speed of the pressure conversion stroke, and the speed reduction processing is not carried out according to the flow difference, namely, the angle calculation algorithm of the present comparative example is always A (i, t i)=AS*stroke+V(i-1)*ti, which causes the stroke calculation angle to exceed the actual value.
The segmentation effect is shown in fig. 8, and the angle calculation result is seriously wrong, namely, the travel angle is far beyond the actual value (fig. 4 is a segmentation diagram after the angle is correctly calculated), so that the construction safety and the construction precision are seriously threatened.
Comparative example 3
The comparative example can obtain a torque-angle curve and a torque stiffness-angle curve based on the angle data obtained by the algorithm, and experimental control analysis is performed on M24 and M20 bolts. In comparison with example 1, the accurate division of the pressure and the noise removal processing were not performed in the present comparative example step S2, the pressure conversion point setting value was deviated in step S3, the specific pressure conversion point was set to 8MPa (larger corresponding to fig. 9 a), the pressure conversion point was set to 8MPa, the high-pressure stage angular velocity ratio was set to 0.1 (larger pressure, smaller angular velocity ratio corresponding to fig. 9 b), and the pressure conversion point was set to 7MPa (smaller pressure, corresponding to fig. 9 c).
The results are shown in fig. 9a-9c, and it can be seen that the difference between the calculation result and the experimental result is obvious, and the error will cause the error of bolt tightening control and even the situation of bolt breaking.
After accurate angle segmentation and angle calculation are implemented, the obtained calculation result is almost consistent with the experimental comparison, the accuracy requirement of replacing the additional angle sensor can be completely met, and a test example is shown in fig. 10.
In summary, the invention not only provides a torsion angle calculation strategy independent of an additional angle sensor based on the structure and the working characteristics of the hydraulic pump station and the hydraulic driving spanner, but also provides a method for accurately dividing the fastening effective section and a method for accurately calculating the angle, thereby ensuring the accuracy of angle monitoring.
The present embodiments are merely illustrative of the invention and not limiting of the invention, and any changes made by those skilled in the art after reading the specification of the invention will be protected by the patent laws within the scope of the appended claims.

Claims (3)

1.不依赖角度传感器的紧固控制方法,其特征在于:包括以下步骤:1. A tightening control method that does not rely on an angle sensor, characterized in that it comprises the following steps: S1. 实时采集液压扳手紧固过程中液压泵的压力数据,得到压力-时间曲线;S1. Real-time acquisition of hydraulic pump pressure data during the tightening process of the hydraulic wrench to obtain a pressure-time curve; S2. 对单个行程的压力-时间曲线分为四个阶段,分别为低压上升段、紧固有效段、高压上升段和回程泄压段;其中第四阶段的压力—时间增加率为负值,其余阶段均为正值且第二阶段的增加率小于第一阶段和第三阶段,第二阶段是压力推动扳手正常扭转的旋转段,为紧固有效段;利用算法对原始压力数据进行区分,分割出紧固有效段;分割原始压力数据的计算方法基于压力-时间增加率特征实现,如式(Ⅰ)所示:S2. The pressure-time curve for a single stroke is divided into four stages: a low-pressure rise stage, an effective tightening stage, a high-pressure rise stage, and a return pressure relief stage. The pressure-time increase rate in the fourth stage is negative, while the remaining stages are all positive. The increase rate in the second stage is smaller than that in the first and third stages. The second stage is the rotational stage where pressure drives the wrench to twist normally, which is the effective tightening stage. An algorithm is used to distinguish the raw pressure data and segment the effective tightening stage. The calculation method for segmenting the raw pressure data is based on the pressure-time increase rate characteristics, as shown in Equation (I): (Ⅰ) (I) 其中:为当前泵输出的原始压力数据,slop1为第一和第三阶段的最小压力升高速率,为人工选定的一小段时间间隔;当等于1时,认为此时的压力转化为了紧固的有效扭矩;将所有结果为1的压力数据在内存中重新储存并拼接,就形成了完整的历史压力数据的分割结果,时间维度也由变为了in: is the original pressure data output by the current pump, slop1 is the minimum pressure increase rate of the first and third stages, A small time interval selected by humans; when When it is equal to 1, it is considered that the pressure at this time is converted into the effective torque of tightening; all The pressure data with the result of 1 is stored again in the memory and spliced together to form the complete segmentation result of the historical pressure data. The time dimension is also Became ; S3. 在第一个有效段结束后,计算有效段的角度-时间关系,获得扳手的转动角速度;S3. After the first valid segment ends, calculate the angle-time relationship of the valid segment to obtain the angular velocity of the wrench; S4. 随后在进入下一个有效段后,基于前一行程的旋转角速度和下一个有效段的行程时间,叠加上一行程紧固角度后,得到当前时刻的紧固角度;紧固角度的计算公式如(II)所示:S4. After entering the next valid segment, the tightening angle of the previous stroke is superimposed based on the rotational angular velocity of the previous stroke and the travel time of the next valid segment to obtain the current tightening angle. The tightening angle calculation formula is shown in (II): (II) (II) 其中,表示第个行程,时刻为的实际转角位置;表示单个行程的固定转动角度,由扳手结构决定;为行程数目;表示上个行程对应压力段的转动角速度,由单个行程转角和上次行程对应压力段时间决定;in, Indicates the trips, time The actual corner position; Indicates the fixed rotation angle of a single stroke, which is determined by the wrench structure; is the number of trips; Indicates the rotational angular velocity of the pressure section corresponding to the previous stroke, which is determined by the single stroke angle and the time of the pressure section corresponding to the previous stroke; 所述液压泵为多级泵,角度计算算法必须感知其流量改变并做出响应,应基于实验测试泵的实际压力转换点,在每个压力转换点所处行程内,对应高压段的紧固角速度需要基于流量关系进行修正,修正系数为在高压段起有效作用的级泵流量与多级泵全流量之比。The hydraulic pump is a multi-stage pump, and the angle calculation algorithm must sense its flow changes and respond. It should be based on the actual pressure conversion points of the experimental test pump. Within the stroke of each pressure conversion point, the tightening angular velocity of the corresponding high-pressure section needs to be corrected based on the flow relationship. The correction coefficient is the ratio of the stage pump flow that plays an effective role in the high-pressure section to the total flow of the multi-stage pump. 2.根据权利要求1所述的不依赖角度传感器的紧固控制方法,其特征在于:步骤S2中,分割原始压力数据的计算方法须通过以下处理实现准确分割与噪声去除:2. The angle sensor-independent tightening control method according to claim 1, wherein in step S2, the calculation method for segmenting the raw pressure data must achieve accurate segmentation and noise removal through the following processing: 第一、须基于实际控制系统的电磁阀加压指令判断行程状态,结合压力是否达到设定最大值来滤除运行误差;First, the stroke status must be judged based on the solenoid valve pressurization command of the actual control system, and the operating error must be filtered out by combining whether the pressure has reached the set maximum value; 第二、结合液压泵低压级大流量泵的机械设置,测试和设定有效行程分割算法的最低压力,滤除回程时的低斜率段干扰;Second, combining the mechanical settings of the hydraulic pump's low-pressure, high-flow pump, test and set the minimum pressure for the effective stroke segmentation algorithm to filter out the low-slope interference during the return stroke; 第三、结合传感器数值波动范围,平衡系统有效段分割灵敏度和斜率波动误差,设定取样时间间隔和斜率判断阈值,以准确分割有效段。Third, based on the sensor value fluctuation range, balance the system's effective segment segmentation sensitivity and slope fluctuation error, set the sampling time interval and slope judgment threshold to accurately segment the effective segment. 3.实现权利要求1-2任一项所述的不依赖角度传感器的紧固控制方法的装置,其特征在于:包括:3. A device for implementing the angle sensor-independent tightening control method according to any one of claims 1 to 2, characterized in that it comprises: 液压泵站(1);Hydraulic pump station (1); 液压扳手(2),通过油管(3)与所述液压泵站(1)连接;A hydraulic wrench (2) is connected to the hydraulic pump station (1) via an oil pipe (3); 压力传感器(4),安装于所述液压泵站(1),实时监测所述液压泵站(1)对液压扳手(2)的施加油压;A pressure sensor (4) is installed on the hydraulic pump station (1) to monitor in real time the oil pressure applied by the hydraulic pump station (1) to the hydraulic wrench (2); 人机交互和电控系统(9),用于接收所述压力传感器(4)的压力数据并形成压力-时间曲线;基于算法对单个行程的压力-时间曲线分割出紧固有效段;基于前一行程的旋转角速度和下一个有效段的行程时间,叠加上一行程紧固角度,输出当前时刻的紧固角度。A human-machine interaction and electronic control system (9) is used to receive pressure data from the pressure sensor (4) and form a pressure-time curve; based on an algorithm, the pressure-time curve of a single stroke is segmented into a tightening effective segment; based on the rotational angular velocity of the previous stroke and the stroke time of the next effective segment, the tightening angle of the previous stroke is superimposed, and the tightening angle at the current moment is output.
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