Dyyy-GY intelligent data collection system Hydraulic high-pressure training device

Release time：2024-06-04 20:30viewed：times

The intelligent data acquisition system hydraulic test bench has a development, test and analysis system that collects, analyzes and processes computer intelligent data through flow, pressure, power, speed, time, temperature, computer human-machine interface, and automatically produces reports, curves, etc. After a series of intelligent actions, experiments such as dynamic and static tests of various conventional hydraulic circuits and various valves and pumps were completed. Through experiments, the performance testing, intelligent control, remote control and communication technology of hydraulic systems and computers can be mastered and improved.

1 Part of the technical requirements of the hydraulic pump station
① It consists of a manual variable plunger pump (used as a quantitative pump to facilitate adjustment of the flow rate) and a pressure-limiting variable vane pump, each with an independent hydraulic circuit.
② The maximum flow rate of the manual variable plunger pump is 80ml/r, the rated pressure is 20MPa, and it is equipped with a 6-stage motor of 30kW; the pressure-limited variable pump (vane pump) has a displacement of 20ml/r, a rated pressure of 12MPa, and is equipped with a 4-pole motor of 7.5kW.
③ Oil tank: The nominal volume is greater than 200L; equipped with liquid level and oil temperature indicators, oil suction and oil return filters, safety valves (separately equipped), respectively equipped with oil return ports, oil outlets, and an oil dr*n port (liquid level). above return to the fuel tank).
④ The pipeline design of the pump station system and the selection of hydraulic components and accessories must meet the maximum working pressure and flow rate of the circuit.
⑤ How to measure the output power of the motor (the input power of the oil pump): measure the input power of the motor, and calculate the output power of the motor (the input power of the oil pump) with the transmission efficiency curve of the motor (provided by the motor manufacturer). The motor and the oil pump are directly connected. .
⑥Hydraulic and pneumatic transmission design and control virtual simulation software

This software is developed based on unity3d. The software adopts the form of three-dimensional roaming. Movement can be controlled by the keyboard and the lens direction can be controlled by the mouse. The interface has home page, help, full screen, component recognition, circuit construction, key component testing, and typical system testing interfaces.
1. Component identification adopts the form of automatic playback, which introduces the m*lbox, liquid level gauge, oil pump unit on the equipment (the pop-up hydraulic symbols, principles and introduction are introduced here, click OK to enter the next introduction), valve frame, and pressure gauge. , sensors , etc.
2. The disassembly and assembly of components is divided into learning mode and assessment mode. There are built-in electromagnetic reversing valves, plate relief valves, plunger pumps, filter valves, and electro-hydraulic servo valves. In the learning mode, the disassembly sequence is prompted and highlighted. There are no prompts for disassembly and installation in assessment mode. If the disassembly and assembly sequence is wrong, the next step of disassembly and assembly will no longer be possible. The toolbar is equipped with draggable seals, pumps, valves, oil filters, hex wrenches, pipe wrenches, adjustable wrenches, dead wrenches, and M5 screws.
3. The hydraulic components are equipped with one-way valve (hydraulic control, poppet valve core, ball valve core), m*n structure of the reversing valve (O type, Y type, H type), hydraulic cylinder (assembled plunger, double-acting single outlet rod) , double-action double-output rod, single-action double-output rod, single-action single-output rod), etc. Each construction experiment adopts a graphical method and is constructed by dragging the set graphics. In the graphics library There are confusing graphics.
4. Hydraulic selection is based on the hydraulic schematic diagram, and then selects the nominal displacement of the pump (12 items, including 11 confusing items) and pressure level (5 items, including 4 confusing items), and the selection of the solenoid relief valve (3 specifications, 3 pressure levels, and 3 flow levels, all of which have confusing items), oil filter selection (multiple choices include confusing items), servo valve selection (multiple choices include confusing items), and the wrong selection system will Automatically prompt the correct answer. After selecting, drag the corresponding tool to the highlighted area according to the prompt.
5. Circuit inspection is done by selecting the correct accessories, including the selection of sealing rings, checking valve switches, etc. Then proceed to the next step to turn on the machine. Follow the prompts to turn on the machine. After turning on the machine, enter the monitoring interface. Turn on the equipment one by one according to the prompts. The prompts are in the form of text and button highlighting.
6. Hydraulic cylinder pressure test Enter the experiment through the test button on the background interface and gradually analyze To start friction test, start friction force, parameter setting, start test, draw curve, stop test.
7. Typical system tests are divided into trial operation, stage response test and frequency response test. The above tests are all conducted through the background monitoring interface.
8. The software must be able to rotate, zoom in and out in all directions to view its det*ls. And the same platform as a whole cannot be displayed as separate resources.
8. Microcontroller and PLC programmable design and control virtual simulation software.
This software is developed based on unity3d. It has built-in task books and experimental prompts. It adopts the form of three-dimensional roaming. Movement can be controlled by the keyboard, the direction of the lens can be controlled by the mouse, and the distance of the picture can be controlled by the mouse wheel. Rotated 360 degrees, the three-dimensional wall has electrical diagrams p*nted on it.
1. Equipment component assembly: Follow the highlighted prompts to find the component control rack. You can drag components from the component library according to the electrical component layout diagram and place them on the component control rack. The component library is equipped with control panels, switching power supplies, micro relays, and PLCs. , frequency converter, stepper motor, AC motor, servo motor, servo driver, stepper driver, interface board, operation panel, circuit breaker, servo motor interface, digital display voltmeter, there will be a prompt when the selection is wrong.
2. Technical indicator measurement: Select the multimeter to check the servo motor connection cable and the servo driver with BOP panel. Adjust the left and right buttons to the ohm level, drag the black and red test leads and insert them into the R, S, T, U, V, W and ground phases respectively for testing. For resistance value, according to the highlighted prompt, find the power switch in the scene, drag the pen or multimeter to measure whether the power is on.
3) Electrical component connection: According to the electrical wiring diagram, connect the power line and control line, highlight the interface, connect the driver, interface board, power line, servo motor, encoder, PLC, and relay in order, and turn on the m*n power supply After turning on the switch, servo power switch, and faulty circuit switch, a fault code will be prompted, and you can select the cause of the fault from three items.
4) Parameter adjustment test: Turn on the power to adjust the speed, set the driver parameters according to the requirements of the mission statement, perform inching control/analog speed adjustment/multi-stage speed control, and observe the three-dimensional servo motor motion control. Select any of the 6 PLC programs and then adjust the servo drive analog speed. The PLC parameters are adjustable. Set the drive parameters and enter the three-dimensional servo motor motion control interface and electrical display interface. The operation panel is equipped with servo start, low speed, medium Speed, high speed, servo stop, torque limit, abnormal reset, forward/reverse rotation selection, 0-10 sliding control (the electrical panel displays the value in real time).
5) Inspect the three-dimensional virtual simulation machine of the servo system mask machine, observe its structure, inject fault points, select multiple fault causes, and locate faults. Connect the fault causes with the corresponding detection and positioning methods, and troubleshoot after selecting the correct ones. Connect the cause of the f*lure with the corresponding solution.
6) Control process plan, optional single machine mode and online mode of inching control/analog speed regulation/multi-stage speed regulation control, call up the control panel, display the operation of 3 production lines, perform real-time control, optional inching, low and medium High speed, start and stop control, adjustable speed. According to the control plan, the system automatically determines the performance of the production line and submits a disclosure record.

configuration list:

	name	quantity	describe	Remark
Experiment bench hydraulic station	1. Manual variable plunger pump	1	Maximum displacement: 80ml/r, rated pressure: 20Mpa, working speed: 1000r/min
	2. Pressure-limiting variable vane pump	1	Maximum displacement: 20ml/r, rated pressure: 12Mpa, working speed: 1500r/min
	3. Relief valve (piston pump circuit)	1	Nominal pressure: 31.5MPa, nominal flow: 100L/min
	4. Relief valve (vane pump circuit)	1	Nominal pressure: 31.5MPa, nominal flow: 30L/min
	5. Stop valve (pressure oil)	2	Maximum working pressure of the adaptation circuit and pressure oil pipeline
	6. Stop valve (oil return)	2	Adapting circuit oil return line
	7. Stop valve (leakage port)	1	Adapted to dr*n pipeline
	8. Oil suction filter (piston pump)	1	Nominal flow rate: 300L/min, filtration accuracy: 80 microns
	9. Oil suction filter (vane pump)	1	Nominal flow rate: 100L/min, filtration accuracy: 80 microns
	10. Return oil filter	1	Nominal flow rate: 300L/min, filtration precision: 20 microns
	11. Motor (piston pump)	1	Rated power: 30KW, number of poles: 6
	12. Motor (vane pump)	1	Rated power: 7.5KW, number of poles: 4
	13. Liquid temperature and level gauge	1	Adapted fuel tank
	14.Air filter	1	Air flow rate: 0.25m³/min, filtration precision: 40 microns
	15. One-way valve (piston pump circuit)	1	Nominal pressure: 31.5MPa, flow range: 100L/min
	16. One-way valve (vane pump circuit)	1	Nominal pressure: 31.5MPa, flow range: 30L/min
	17. Pressure gauge (piston pump circuit)	1	Measuring range: 0~25MPa
	18. Pressure gauge (vane pump circuit)	1	Measuring range: 0~16MPa
	19. Fuel tank 200L	1

2 Part of the technical requirements for the experimental bench
① The experimental bench needs to meet the working intensity requirements under the system's maximum working pressure of 20MPa. The experimental bench is equipped with drawers, storage cabinets and placement brackets. The experimental platform is designed with an oil return pan; the base is equipped with an automatic The universal wheels with lock structure facilitate the movement and positioning of the equipment.
② The installation panel of the experimental bench is a profile structure with a "T" groove, which can conveniently and optionally install hydraulic components and overlap the experimental circuit. T-slot panel, area: 1200*720, meets the working strength requirements of the system under the maximum working pressure of 20MPa, and is installed vertically.
③ Connection method: The hydraulic connection method adopts quick-change joints, and there is no oil leakage during use.
④ Material list:

	name	quantity	describe	Remark
Experimental bench	1.T-slot panel	1	Area: 1200*720, vertical installation
	2. All steel experimental bench	1
	3. Components are stored in cabinets	1
	4.Drawer	1
	5. Electrical cabinet	1
	6. Oil return pan	2
	7. Universal wheel	6

3. Technical requirements of the data acquisition unit:
A personal computer is used as the m*n body to form the entire data acquisition and measurement system: select the appropriate data acquisition interface card, and use the analog multi-channel switch, program-controlled amplifier, and sample/holder assembled on the data acquisition interface card. , A/D converters and other devices to collect data; use data acquisition interface cards and computer interfaces to jointly complete data processing and display of pressure, flow, and speed.
Material list:

	name	quantity	describe	Remark
data acquisition unit	1. Computer	1
	2.Display	1
	3. Data acquisition card	1
	4. Data collection procedures	1

4 Technical requirements for electronic control unit
① Electrical components: The programmable controller (PLC) brand is Siemens or Mitsubishi, the power supply brand is T*wan's MEAN WELL, the electrical switch brand is HGG, the relay group brand is Japan's Omron, and the AC contactor The brand is Schneider. It is also equipped with a relay group, solenoid valve electronic control unit, electrical button module and time relay module. The electrical access ports are all attached to the electrical control panel of the experimental bench. Experimental wires can be used to facilitate plug-in connections during experiments.
② Safety performance: The equipment is equipped with electrical grounding, leakage protection (automatic power-off when the ground leakage current exceeds 30mA), phase loss protection, and DC overload protection. The control circuits are all 24V DC safety voltage, and the electrical wires are safety high-insulation experimental wires.
③ Multiple control methods: PLC control, relay control, manual control and other control methods.
④ Material list:

	name	quantity	describe	Remark
Electronic control unit	1. Programmable controller (PLC)	1	Input and output 20 points, relay form, control voltage is DC24V	Siemens or Mitsubishi
	2. Programmable control communication cable	1 set	SC-09 data transmission cable
	3. Stabilized power supply	1	WV outputs DC24V 4.5A DC12V 1.5A respectively
	4. Power start and stop module	1 set	Cont*ns three-phase four-wire leakage protection (output 380V/220V)
	5. AC contactor	2
	6. Button module	1 set	Start button, programmable controller input and output, etc.

5 Technical requirements for hydraulic components/accessories of the experimental bench
① Be able to complete the construction of conventional hydraulic circuits. The maximum pressure of the system during the experiment is 20MPa.
② Each hydraulic component is equipped with a mounting base plate, which allows the hydraulic components to be placed on the experimental panel conveniently and arbitrarily.
③ The oil circuit overlap adopts quick-change joints, which are easy to disassemble and connect without oil leakage.
④ Material list (hydraulic valve brand: Beijing Huade):

	name	quantity	describe	Remark
Experiment bench hydraulic components	1. One-way throttle valve	2	DVP12 one-way throttle valve, maximum pressure 35MPa
	2. One-way valve	2	S10A tubular one-way, flow rate: 30L/min, maximum pressure 31.5 MPa, thread diameter M16
	3. Hydraulic control check valve	2	SV10PB1 hydraulic control check valve, diameter: φ10, maximum flow: 80L/min, minimum starting pressure: 0.5MPa
	4. Direct-acting relief valve	2	DBDH6P plate maximum flow: 100L/min, maximum pressure 31.5MPa
	5. Pilot relief valve	1	DB10 pilot overflow, diameter: 10, pressure adjustment range: 0-31.5MPa, maximum flow: 200L/min
	6. Sequence valve	2	DZ10 maximum flow: 150L/min, maximum pressure: 31.5MPa, pressure adjustment range: 0.3-21 MPa
	7. Speed regulating valve	2	2FRM5 one-way speed regulating valve, rated flow 15L/min, working pressure 21 MPa
	8.Pressure reducing valve	1	ZDR6DA, maximum flow rate 60L/min, pressure adjustment range: 0.3-25 MPa, maximum pressure 31.5MPa
	9. Two-position three-way solenoid directional valve	1	3WE6A61B two-position three-way, flow rate: 60L/min, equipped with transition oil manifold, diameter φ8, DC 24V coil, equipped with wire connector
	10. Two-position four-way solenoid directional valve (single)	2	4WE6C two-position four-way, flow rate: 60L/min, equipped with transition oil manifold, diameter φ8, DC 24V coil, equipped with wire connectors
	11. Three-position four-way solenoid directional valve (O)	1	4WE6E61B three-position four-way flow rate: 60L/min, equipped with transition oil manifold, diameter φ8, DC 24V coil, equipped with wire connector, with LED display
	12. Three-position four-way solenoid directional valve (M)	1	WE6G61B three-position four-way, flow rate: 60L/min, equipped with transition oil manifold, diameter φ8, DC 24V coil, equipped with wire connectors
	Three-position four-way solenoid directional valve (H)	1	4WE6J61B three-position four-way, flow rate: 60L/min, equipped with transition oil manifold, diameter φ8, DC 24V coil, equipped with wire connectors
	Two-position four-way manual directional valve	1	4WMM6C50B two-position four-way, flow rate: 60L/min, equipped with transition oil manifold, diameter φ8, DC 24V coil, equipped with wire connectors
	four links	3
	Double acting hydraulic cylinder	2	Stroke 200mm, rod diameter to piston ratio 1:2
	loading board	1 piece	Made of 15mm thick metal plate and built into the experimental bench
Experiment bench accessories	high-pressure hose	1 set	Pipe diameter and interface adaptation, maximum working pressure 31.5MPa
	Open and close type quick connector (male connector)	1 set	With automatic closing function, no oil leakage when connected
	Open and close type quick connector (female connector)	1 set	With automatic closing function, no oil leakage when connected
	Joints, hydraulic base plate seals	1 set	For hydraulic parts
	Hydraulic component base plate	1 set	Adaptable to the working pressure of components, it can be quickly built on a T-slot platform
	fixed bracket	1 set	For installation of base plate
	Hydraulic oil		Anti-wear hydraulic oil 32#

6 Technical requirements for experimental bench instrumentation
① Use pressure sensors and flow sensors to measure the pressure and flow in the experimental system respectively.
② In order to measure the speed of the piston rod of the hydraulic cylinder, a displacement sensor can be installed on the piston rod.
③ Material list:

	name	quantity	describe	Remark
Test bench instrumentation	Pressure Transmitters	4	Measurement accuracy: 0.5%, measurement range: 0~25MPa
	flow transmitter	1	Measurement accuracy: 0.5%, nominal pressure: 25MPa, measurement range: 0~100L/min
	Motion detector	2	Measuring accuracy: 0.5%, measuring range: 0~200mm, can be installed on the double-acting hydraulic cylinder matching the experimental bench

The cooling tower needs to be prepared by the customer.

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