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Melnikov Roman Vyacheslavovich. Improving methods for diagnosing hydraulic drivers of construction and road machines based on studies of hydrodynamic processes in hydraulic systems: the dissertation ... Candidate of Technical Sciences: 05.05.04 Norilsk, 2007 219 p. RGB OD, 61: 07-5 / 3223
Introduction
Chapter 1. Analysis existing system Then the general question of the question of the dynamics working fluid
1.1. The role and place of diagnosis in the system of maintenance system of hydraulic drives SDM
1.2. General condition of the hydrodynamics of hydraulic drive SDM 17
1.3. Research Research on Hydraulus Dynamics
1.3.1. Theoretical studies 24.
1.3.2. Experimental studies 42.
1.4. The use of electro-hydraulic analogies in the study of wave processes in the RS in hydraulic systems SDM
1.5. Overview of the diagnostic methods of hydraulic SDM 52
1.6. Conclusions on the chapter. Purpose and objectives of research 60
Chapter 2. Theoretical studies of hydrodynamic processes in relation to hydraulic systems SDM
2.1. Investigation of the distribution of the main harmonic of the SDM hydraulic system
2.1.1. Modeling the passage of the main harmonics through obstacles
2.1.2. Definition B. general Transmission function of a bilateral action
2.1.3. Determination of pressure in hydrolynium with an oscillating excitation by solving a telegraph equation
2.1.4. Modeling the propagation of waves in hydrolyania based on the method of electrohydraulic analogies
2.2. Evaluation of the magnitude of the shock pressure in the hydraulic systems of construction machines on the example of the DZ-171 bulldozer
2.3. Dynamics of the interaction of the pulsating stream of the RJ and the walls of the pipeline
2.4. Interrelation of oscillations of the walls of hydrolynes and internal pressure of the working fluid
2.5. Conclusions on chapter 103
Chapter 3. Experimental studies of hydrodynamic processes in hydraulic systems SDM
3.1. Justification of the techniques of experimental research and the choice of variable parameters
3.1.1. General. Objective and objectives of experimental research
3.1.2. Methods of processing experimental data and estimation of measurement errors
3.1.3. Determination of the form of the regression equation 106
3.1.4. Methodology and procedure for conducting experimental studies
3.2. Description of equipment and measuring instruments 106
3.2.1. Stand for the study of wave processes in hydraulic systems
3.2.2. Vibration analyzer SD-12M 110
3.2.3. AR-40 110 Vibration Sensor
3.2.4. Digital tachometer / stroboscope "Aktakak" ATT-6002 111
3.2.5. Hydraulic press 111.
3.3. Study of the static deformation of high pressure sleeves under load
3.3.1. Research of radial deformation of the RVD 113
3.3.2. Study of the axial deformation of the RVD with one free end
3.3.3. Determination of the form of the regression equation p \u003d 7 (DS1) 121
3.4. To the question of the characteristics of Vibrations of the SDM in various fields of the spectrum
3.5. Investigation of the wave propagation rate and decrement of the attenuation of a single pulse in MG-15 liquid
3.6. Investigation of the nature of pressure pulsations in the hydraulic system of the EO-5126 excavator for vibrations of hydrolynes walls
3.7. Hydrodynamics of the working fluid in the hydraulic system of the DZ-171 bulldozer when the dump is lifted
3.8. Investigation of the dependence of the amplitude of the main harmonic from the distance to the throttle slot
3.9. Conclusions on chapter 157
4.1. Selection of diagnostic parameter 159
4.3. Criterion for the presence of a punch 165
4.4. Characteristics of the analogues of the proposed method 169
4.5. Advantages and disadvantages of the proposed method 170
4.6. Examples of concrete application 171
4.7. Some technical aspects of the proposed diagnostic method
4.8. Calculation of the economic effect from the introduction of the proposed express method
4.9. Evaluation of the effectiveness of the implementation of the express diagnostic method
4.11. Conclusions on chapter 182
Conclusions for work 183
Conclusion 184.
Literature
Introduction to work
Relevance of the topic.The efficiency of maintenance of construction and road machines (SDM) largely depends on the qualitative implementation of the technical diagnostics of the machine and its hydraulic line, which is an integral part of most SDMs in recent years in most sectors of the national economy, there is a transition to maintenance of construction and road equipment on the actual technical state, allowing to exclude unnecessary repair operations Such a transition requires the development and implementation of new methods for diagnosing hydraulic drives SDM
Diagnosis of hydraulic drive often requires assembly and disassembly, which is associated with significant time costs reduction of time for diagnostics is one of the important maintenance tasks of the SDM, its solution is possible by various ways, one of which is the use of methods of unemploy diagnosis, including vibration at the same Time, one of the sources of vibrations of machines are hydrodynamic processes in hydraulic systems, and according to the parameters of vibrations, one can judge the nature of the hydrodynamic processes occurring and on the state of the hydraulic line and its individual elements
By the beginning of the XXI century, the possibility of vibration diagnostics of rotating equipment increased so much that it was based on the maintenance of the maintenance and repair of many types of equipment, for example, ventilation, according to actual state however, for hydraulic drives, the nomenclature of the defects detectable on the vibration of defects and the accuracy of their identification are still insufficient To make such responsible solutions
In this regard, one of the most promising methods for diagnosing І iDrevodovov SDM are methods of impact vibration diagnostics, based on the analysis of the parameters of hydrodynamic processes
Thus, the improvement of the methods for the diagnosis of hydraulic means of construction and road machines based on studies of hydrodynamic processes in hydraulic systems is actualscientific and technical problem
The purpose of the dissertation workit is to develop methods for diagnosing SDM hydraulic drivers based on the analysis of the parameters of hydrodynamic processes in hydraulic systems
To achieve the goal, it is necessary to solve the following tasks
Explore modern condition Question of hydrodynamics
Hydraulus SDM and find out the need for hydrodynamic
processes for the development of new diagnostic methods
hydraulic drives SDM,
build and explore mathematical models of hydrodynamic processes occurring in SDM hydraulic systems,
Experimentally explore hydrodynamic processes,
flowing in hydraulic systems SDM,
Based on the results of studies to work out
Recommendations for improving diagnostic methods
SDM hydraulic system,
Object research- hydrodynamic processes in SDM hydroplaring systems
Research subject- patterns that establish relations between the characteristics of hydrodynamic processes and methods for diagnosing hydraulic drives of the SDM
Research methods- Analysis and generalization of existing experience, methods of mathematical statistics, applied statistics, mathematical analysis, method of electro-hydraulic analogies, methods of the theory of equations of mathematical physics, experimental studies on a specially created stand and on real cars
Scientific novelty of dissertation results:
A mathematical model of the passage of the first harmonic of pressure pulsations created by the volume pump (main harmonics) was drawn up, and general solutions of the system of differential equations describing the spread of the main harmonic of hydrolyanium,
Analytical dependencies were obtained to determine
internal pressure fluid in the RVD on the deformation of it
multi-metal elastic shell,
The dependences of the deformation of the RVD from the internal
Pressure
Experimentally obtained and studied spectra of vibrations
Hydroral elements in the EO-5126 GS Excavator, Bulldozers D3-171,
self-propelled boom crane KATO-1200S under operating conditions
a method of vibration identification of SDM hydraulic systems, based on the analysis of the parameters of the main harmonic of pressure pulsations generated by the volume pump,
the criterion for the presence of pins in the SDM hydraulic system is proposed when they are used by the new method of non-band technical diagnostics,
the possibility of using the parameters of hydraulic shocks, resulting from delaying safety valves for the diagnosis of the SDM
The practical value of the results obtained.
offered new way Vibrodiagnostation for localization of faults in the elements of the hydroplaring of the SDM,
a laboratory stand has been created to study hydrodynamic processes in hydraulic systems,
The results of the work are used in the educational process in
lecture course, during coursewards and thesis design, and
Created laboratory settings are used when conducting
laboratory work
Privatecontribution applicant.The main results were obtained by the author personally, in particular, all analytical dependencies and methodical development Experimental studies When creating laboratory stands by the author, the author suggested a common layout, the main parameters were calculated and the characteristics of their main nodes and agreates in the development of a vibration drug method The author belongs to the idea of \u200b\u200bchoosing the main diagnostic attribute and methods of its practical implementation under operating conditions The author personally developed programs and techniques of experimental studies. Research has been conducted, and summarized their results, recommendations for the design of the GS OGP are developed taking into account the wave processes
Approbation of the results of work.The results of the work were reported on NTK of the Norilsk Industrial Institute in 2004, 2005 and 2006, on the VIT of the All-Russian Scientific and Practical Conference of Students, Graduate Students, Doctoral Students and Young Scientists "Science of the Century of Age" MGTU in Maikop, on the Scientific and Pratty Conference "Mechanics - XXI VEK »BRGTU in Bratsk, on the 1st" All-Russian scientific and practical conference of students, graduate students and young scientists "in Omsk (Sibadi), at the All-Russian Scientific and Practical Conference" The role of mechanics in creating effective materials, structures and machines XXI
century "in Omsk (Sibadi), as well as on scientific seminars of the TMIO Research Institute in 2003, 2004, 2005 and 2006 The defense is taken out -
scientific substantiation of the new method of express diagnostics of SDM hydraulic systems based on the analysis of hydrodynamic parameters processesin Gs
justification of the efficiency of using the proposed method of imbalance technical diagnostics,
Publications.According to the results of the studies, 12 printed works were published, including 2 articles in publications included in the list of VAC leading peer-reviewed journals and publications, an application was submitted for a patent for the invention.
Communication themes of work with scientific programs, plans and themes.
The topic is developed as part of the initiative state budget topic "Improving the reliability of technological machines and equipment" in accordance with the NIR plan of the Norilsk Sixtural Institute for 2004-2005, in which the author participated as a performer
Implementation of work.Operational tests of the express method of searching for brokets were carried out, the results of the work were made to introduce into the technological process at the MU "Autorashide" of Norilsk, and also used in the educational process in the GOVPO Norilsk Industrial Institute
Structure of work.The dissertation work consists of the introduction of four chapters fromconclusions, conclusions, list of used sources, including 143 names, and 12 applications The work is set out on 219 pages, including 185 pages of the main text, contains 12 tables and 51 drawing
The author considers it necessary to express gratitude to Melnikov in and, Canda Tehn Sciences, associate professor " Technological machines and equipment "(TMIO) GOVPO Norilsk Industrial Institute (Research Institute), and Bashkirov B in, Training Master of the Department of TMIO for the help provided during the performance of work
Basic maintenance
In the introductionthe relevance of the topic of the thesis is justified, the purpose of the work is indicated, the scientific novelty and practical value are formulated, given summary work and information about its approbation
In the first chapterthe modern system of maintenance SDM is considered, while it is indicated that the technical diagnosis of the technological process of TIR is occupied, which happens two main types of general diagnosis (D-1) and in-depth diagnostics (D-2)
A comparative analysis of existing diagnostic methods was also carried out, while the acceptance of the vibration methods was made by one of the most frequently used methods in the practice of methods is a statchmetric method based on the analysis of the parameters of the assigned working fluid flow, this method is convenient because it makes it possible to accurately identify the location of the malfunction, allows During the diagnosis, it is also adjusting and running the hydraulic system at the same time, this method requires assembly and disassembly, which leads to significant labor costs and leads to additional downtime of machines. Therefore, one of the directions of the committee of the TIR system is the development of impact diagnostic methods, in particular methods based on the analysis of the parameters of hydrodynamic processes in the working fluids
However, currently defects detected by vibration diagnostic systems do not have quantitative characteristics similar to those that have the structural parameters of the object in particular, during vibration diagnostics are not defined, for example, geometrical dimensions Elements, gaps of gaps and T n Quantitative estimates of detectable defects may be considered a probabilistic assessment of the risk of occurrence of an accident in the further operation of the equipment therefore, therefore, the name of the detectable defects often does not correspond to the names of the defiations of the status of the element from normal, which are controlled during the defecting of equipment nodes and quantitative estimates of defects remain open and remain open and issues of quantitative determination of the efficiency of vibration diagnostic systems
One of the most promising methods for modeling processes in hydraulic systems is the method of electro-hydraulic analogies, in which each element of the hydraulic system is put in accordance with a certain element electrical circuit Replacement
The general state of the formation of hydrodynamics of the working fluid in bulk hydraulic systems was investigated, and a review of works on this issue was determined that hydrodynamic processes have
a significant impact on the performance of the machines is indicated that in a practical aspect, namely in the aspect of improvement performance characteristics First of all, the energy-intensive harmonics of a large amplitude, therefore, when conducting research, it is advisable to focus on them, first of all on them, that is, on low frequency harmonics
According to the research results, the goal and research objectives are formulated.
In the second chapterthe results of theoretical studies of the hydrodynamic processes in the RS, the question of the passage of waves through the obstacle was investigated, and on this basis, transmission functions were obtained for the passage of waves through some elements of hydraulic systems in particular, the transfer function for a certain obstacle in the form of a slot in a constant cross section.
4 - ( J.>
w. = ^-= -.
where but]- amplitude of a falling wave, but 3 - the amplitude of the wave pasted through the gap, to- The ratio of the cross section of the pipe to the opening area
For monotoko about the hydraulic cylinder of the two-way effect if the premises, the transfer function will be viewed
1**" (2)
W. =-
{1 +1 ") to " +1?
where t. - The attitude of the area of \u200b\u200bthe piston to the square area, to -the attitude of the piston area to the pill area, U -the ratio of the area of \u200b\u200ban effective cross-section of hydrolynes to the piston area. In addition, the internal diameters of the drain and pressure hydrolynes are assumed to be equal to each other.
Also in the second chapter, on the basis of the method
Electro-hydraulic analogies modeling
the propagation of the harmonic wave along the hydraulic line with distributed parameters is known to the equations describing the GOK and the voltage in the line as the coordinate function x Nt.
I y _ di
where R 0 is the longitudinal active resistance of the line length unit, L 0 - the inductance of the line length unit, CO - the capacity of the line length and G 0 - the transverse conductivity of the lines of the line of the lines of the lines of the electrical line is presented in Figure 1
-1-Mr.
The well-known solution of the system (3), expressed through voltage and current at the beginning of the line, has the form
U.= U, CH (YX) -/, Z. B.sh (yx)
l \u003d i, c) i [) x) - ^ -, h () x)
V№ № + Y) l.about)
constant distribution
\\ P + / SG ~ ~~wave resistance
Neglecting leaks, that is, believing the hydraulic equivalent G. 0 equal to Іgul, we obtain the equation to determine the harmonic function of pressure and consumption at any point of the line, expressed through pressure and consumption at the beginning of the line
I. Q \u003d p, ch (y LX) - Q- S.h (Y. R.x)
Q.- Volumetric flow, 5 - section of the pipe, I - Pressure, p \u003d R. E.>-",
Q \u003d Q. E." sh+*>) , from- wave propagation rate, P 0 - density, but -
the friction parameter, CO - the circular frequency of the wave after substitution to the system (4) of the hydraulic analogs of electrical values, system solution was obtained (5)
I\u003e \u003d L \\ CF \\ X- ^ + ^- (-sinh + jcosh
- V. \\ s \\ r,
V../,. 4l ", __ j / rt ..._," "j _".!,. 4 *. " (_ 5Ш ^) + USO F)) | (eight)
Є \u003d 0 x | * -4I + - (-sm (9) + V cos (i9))
Ї 1 + 4h (COS (0) - 7 SMH) V o) PI
Taking into account the reflected wave, pressure in hydrolynia as a function of coordinates and time takes
where R () N. - the wave generated by a volumetric pump determined by the expression (8), r -reflected wave
P ^ \u003d u, ") joint venture (g (l-x)) k 0 -Q (i, t) 7"Sh ( K. (L - X)) k 0 (10)
where the reflection coefficient is determined by the expression R. _ Zii-zlb. - z "- hydraulic load resistance ~7 +7
The resulting model is valid not only for hydrolynes with absolutely rigid hydrolynes walls, but also for the RVD in the latter case, the wave propagation rate should be calculated according to a known formula
where g -hydrolyania radius d -wall thickness, To -the reduced volume module of fluid elasticity
The maximum value of pressure casts was evaluated. In the event of hydraulic shocks in the hydraulic system of the DZ-171 Bulldozer (base machine T-170), arising from the stopping of the rope lift hydraulic cylinders, the resulting value was AR, By 24.6 MI FA.Pr and the occurrence of the hydroudar, in case of delay
the operation of the safety valves for a while is 0.04 ° C, theoretically maximal pressure of the pressure in the hydraulic system of the specified machine is 83.3 MPa
Due to the fact that the measurements were supposed to be carried out on real machines by the impact method, the question of the relationship of the amplitude of vibration and vibrating the external walls of pressure hydrolynes and the amplitude of pressure pulsations in hydrolynas The resulting dependence for the rigid pipe has a view
dHF. ^ (d (p\u003e : -GCR. "І ^ + ^ -I
where x, -the amplitude of the vibration of the wall of the pipe on І-RІ.Іarmonica E -jung module for wall material, d -internal hydrolyne diameter, D.- external hydrolyne diameter, r" -liquid density r Art - the density of the material of the walls of hydrolynas, sh, - frequency Mr Harmonics.
V V.h / D. C. LR
H ^ 4 H.
Figure 2 - Calculated scheme To determine the analytical dependence of the deformation of the metal braid of the RVD o g of amplitude of the pulsations of the Vigrene Pressure
Similar dependence of the multilayer metal braid of the flexible hose
reinforced (13)
where T. - number of RVD braids „ - the number of strands in one section of one
braids to but - depreciation coefficient of outdoor clamps, s! - area
cross-section of one wire braid, but -the angle of inclination towards the plane perpendicular to the axis of the cylinder (Fig. 2), x, -the value of the amplitude of the vibration venue / Harmonics, d -diameter of one wire braid, Do -the reduced diameter of all RVD braids, S. L. -
the value of the magnitude of the amplitude of the 7th harmonics at the frequency (O. I., (r -the angle of rotation of the radial beam connecting the point on the screw
lines and under 90 axis cylinder (sleeves), W. J.- the volume of fluid concluded inside the RVD in the loop area loop, V. cm. - the volume of the wall part corresponding to the contour of the thread y \u003d d 8 u D E 5 - wall thickness of the RVD,
th? CP - average diameter of RVD, r J.- liquid density
After solving equation 13 for the most common case, i.e. at a \u003d 3516, "and neglecting the inertia walls of the RVD walls compared to the strengths of the braids, simplified dependence was obtained
d. R = 1 , 62 Yu*^± H. , ( 14 )
Do.і
The third chapter presents the results of experimental studies
To justify the possibility of measuring the parameters of hydrodynamic processes in the RJ with the help of overhead sensors, a study of the dependence of the static deformation of the RVD of the Internal Pressure was investigated by the RVD of the brand - B-29-40-25-4-in Tu-38-005-111-1995, designed for nominal Pressure R nom \u003d 40 MPa The characteristic of the RVD length is 1.6 m, the inner diameter is 25 mm, the outer diameter - 40 mM, the number of braids - 4, the diameter of the wire braid - 0.5 mm, the radial and axial deformation of the RVD was investigated when the pressure is changed from 0 to 12 MPa
For RVD with both fixed ends addiction
radial deformation from pressure is presented in Figure 3 established,
that RVD behaves differently as pressure (upper curve
in Fig 3 A) and b)), and with a decrease in pressure (the lower curve in Fig 3 A) and
b)) Thus, the existence of a known phenomenon was confirmed
Hysteresis during RVD deformation work spent on deformation
for one cycle for one meter of length of this RVD, it turned out to be the same for
both cases - 6.13 j / m installed also that with large
Pressures (\u003e 0.2p, IOVI) Radial deformation remains practically
the constant such differentiation is likely to be explained by
that on a plot from 0 to 8 MPa diameter increment is due to
the main sample of the backs between the layers of the metal braid, and
also deformation of the non-metallic basics of the hose last
circumstance means that at high pressures damping
The properties of the hydrolyania itself are insignificant, parameters
hydrodynamic processes can be investigated according to the parameters of hydrolynes vibrations by the method of final differences, it was found that the optimal equation of regression describing the dependence P \u003d J.
Difficulties of uninstructed detection of a faulty node lead to an increase in maintenance and repair costs. When determining the causes of the failure of any element of the system, it is necessary to produce assembly and dissemination.
Considering the latter circumstance, high efficiency have ways to impairly technical diagnostics. In connection with the rapid development in recent years of computing equipment, the cheapening of hardware and software for digital measuring instruments, including vibrationanalysts, a perspective direction is the development of methods of non-drug vibration diagnostics of SDM hydraulic drivers based, in particular, on the analysis of hydrodynamic processes in the HS.
Determination in the overall form of the transfer function of the bilateral action
Pressure pulsations created by it in the SDM hydraulic system can be decomposed on harmonic components (harmonics). At the same time, the very first harmonic has, as a rule, the greatest amplitude. We will call the first harmonic of pressure pulsations created by it, the main harmonic (GT).
In general, building mathematical model To distribute the main harmonics on pressure hydrolynium from the source (pump) to the working body, it is a time-intensive task that should be solved for each hydraulic system. In this case, gear ratios for each hydraulic system (sections of hydrolynes, hydraulic apparatuses, valves, local resistances, etc.), as well as feedback between these elements should be determined. You can talk about the presence of feedback in the event that the wave propagating from the source interacts with the wave propagating towards the source. In other words, feedbacks occur when interference in the hydraulic system occurs. Thus, the transfer functions of the elements of the hydraulic system should be determined not only depending on constructive features Hydraulus, but also depending on the modes of its work.
The following algorithm for the construction of Matmodel spread the propagation of the main harmonic in the hydraulic system is proposed:
1. In accordance with the hydraulic scheme, as well as taking into account the operation modes of the hydraulic system, the structural scheme of the mathematical model is drawn up.
2. Based on the kinematic parameters of the HS, the presence of feedback is determined, after which the structural scheme of Matmodel is adjusted.
3. The choice of optimal methods for calculating the main harmonics and its amplitudes at different points of the HS is made.
4. The transfer ratios of all hydraulic systems, as well as the transfer ratios in operator, symbolic or differential form, based on the previously selected methods of calculation is determined.
5. The GG parameters are calculated at the required points of the HS.
It should be noted several patterns of matms of the passage of GG on hydraulic systems SDM.
1. The law of distribution of the main harmonics in the general case does not depend on the presence (absence) of branches from hydrolynia. The exceptions are cases when the length of the branches of the quarter of the quarter of the wavelength, that is, those cases where the necessary condition for the occurrence of interference is performed.
2. Feedback depends on the mode of operation of the hydraulic line, and can be both positive and negative. Positive is observed in the occurrence of resonant modes in the hydraulic system, and negative - in the occurrence of anti-conant. Due to the fact that gear ratios depend on a large number of factors and can change when changing the mode of operation of the hydraulic system, positive or negative feedback is more convenient to express (unlike systems automatic control) In the form of a plus sign or minus before the transfer function.
3. The examination of the harmonic can serve as a factor initiating a number of secondary harmonic components.
4. The proposed method of constructing Matmodel can be used not only in the study of the law of distribution of the main harmonics, but also in the study of the law of behavior of other harmonics. However, due to the above circumstances, the transfer functions for each frequency will be different. As an example, consider Matmodel spread the main harmonic on the hydraulic system of the DZ-171 Bulldozer (Appendix 5). D2.
Here l is the pulsation source (pump); DL, D2 - vibration sensors; Wj (p) -bid function of hydrolyania on a plot from the pump to ok; \\ Ultrasound (p) - OK function OK; W2 (P) is a transmission function for a wave reflected from OK and propagating back to the pump; W4 (p) -bid function of the hydrolynee site between OK and the distributor; WS (P) - the transfer function of the distributor; W7 (P) and W8 (P) - transmission functions of waves reflected from the distributor; W6 (P) is the gear ratio of the hydrolynium section between the distributor and hydraulic cylinders 2; W p) -bind function of the hydraulic cylinder; WN (P) is the gear ratio of hydrolynas on the area from the distributor to the filter; Wi2 (P) - the transfer function of the filter; Wi3 (P) - the gear ratio of the hydraulic system for a wave reflected from the piston of the hydraulic cylinder.
It should be noted that for a good hydraulic cylinder, the transfer function is 0 (the wave through the hydraulic cylinder in the absence of a blows does not pass). Based on the assumption that the pins in the hydraulic cylinders are usually small, then feedback between the filter, on the one hand, and the pump, on the other, neglect. Modeling the passage of the main harmonic through obstacles. Consideration of the passage of the wave through an obstacle is generally a physical task. However, in our case, on the basis of physical equations, the process of passing the wave through some elements of hydraulic systems will be considered.
Consider hydrolynes with the cross section of Si, having a solid obstacle with the sinter hole S2 and the width of the г. First, we first define the ratio of amplitudes of the incident wave in hydrolynia 1 (TFJ) to the amplitude of the wave of the past in the slot 2 (Fig. 2.1.2). In hydrolynia 1 contains incident and reflected waves:
General. Objective and objectives of experimental research
The data obtained in the second chapter made it possible to formulate the tasks of experimental studies in the third chapter. Objective of experimental studies: "Obtaining experimental data on hydrodynamic processes in HDM hydraulic systems" The tasks of experimental studies were: - study of the properties of the RVD under pressure in order to study the adequacy of the measured parameters of the oscillations of the outer walls of the RVD parameters of the hydrodynamic processes in hydraulic systems SDM; - determination of the decrement of the attenuation of waves in the RS used in the hydraulic systems of the SDM; - study of the spectral composition of pressure pulsations in SDM hydraulic systems containing gear and axial-piston pumps; - study of the properties of shock waves arising in SDM hydraulic systems during machines; - Study of patterns of wave propagation in the RJ.
The calculation of the errors of the measured quantities was carried out using statistical methods. Approximation of dependencies was carried out by regression analysis based on the least squares method, under the assumption that the distribution of random errors is normal (Gaussian). The calculation of measurement errors was carried out according to the following relations: CJ \u003d JO2S + C2R, (3.1.2.1) where the systematic error JS was calculated according to the following dependence: r \u003d T1 GGL + G2O (3.1.2.2), and the accidental error of al - from the theory of small samples. In the above formula, the error of the device; T0-random error. Checking the compliance of the experimental distribution is normal with the help of the criterion of Pearson's consent: NH ,. where and. \u003d - (p (UT) Theoretical frequencies, P \\; - empirical frequencies; p (and) \u003d - \u003d e and2 \\ n - sampling volume, H is a step (the difference between two adjacent l / 2g options), AB is a secondary quadratic Deviation, and, \u003d - To confirm the conformity of the samples under study, the "Criterion W" was used to confirm the samples of the distribution, which is applicable for samples of a small volume.
According to one of the consequences of the Taylor theorem, any function, continuous and differentiable on some plot, can be presented with some error in this area as a polynomial pm degree. The order of the polynomial P for experimental functions can be determined by the method of finite differences [B].
The tasks of experimental studies marked at the beginning of the section were solved in the same sequence. For greater convenience, the technique, the procedure for conducting and the results will be given for each experiment separately. Here we note that tests on real cars were carried out in the conditions of the garage, that is, the technique was indoors in a closed room, the ambient air temperature was + 12-15C, and before starting measurements, the pumps were worked on idling For 10 minutes. The force with which the Piezodatchik pressed against hydrolynium, -20n. The center of the sensor concerned hydrolyania in all measurements carried out on hydrolynes.
A prerequisite for studying wave processes is empirical studies on special laboratory stands and installations. In the field of oscillatory processes, complex systems with volumetric pumps and hydrolynes with distributed parameters are not sufficiently studied by hydraulic systems.
To study these processes, a laboratory installation was developed and manufactured, presented by Naris. 3.1.
The installation consists of a vertical frame (1) installed on a stable base (2), the tank is mounted on the frame (3), the gear Motor pump BD-4310 (USA) (4), the safety valve (5), suction (6) and pressure (7) highways, overclocking section (8), hydraulic reserves (9), adjusting load valve (choke) (10), drain highway (11), pressure sensor (12), pressure gauge (13), autotransformer (14), Lowing transformer (15).
Adjustable stand parameters are: the length of the acceleration section, the speed of the electric motor and the drive shaft of the gear pump, the rigidity of the hydraulic surfactant, the pressure drop on the adjustable loading valve, the adjusting valve.
The stand measuring instruments are a pressure gauge (13), which fixes the pressure in the pressure line, the high-frequency pressure strain gauge on the acceleration site, the CD-12M vibrationanalyzer, the tachometer for measuring the rotational speed of the electric motor shaft.
In addition, in the process of experiments, an oil change is provided, with measuring its parameters (in particular viscosity), as well as a change in the stiffness of the hydrolynes of the acceleration area. The embedding option is provided in the hydraulic focused elasticity of the bellows with the possibility of adjusting its own oscillation frequency using interchangeable goods. The inner diameter of rigid hydrolynes is 7 mm. Material hydrolynes - steel 20.
The stand adjustment range in combination with interchangeable equipment allows you to investigate resonance and anti-conant processes in pressure hydrolynes, determine the reduced wave reflection coefficients from the pneumatic hydro-imorter (9). Alternatively provides for a change in the temperature of the working fluid, to study its effect on viscosity, the elasticity and the speed of the wave propagation.
The stand is made on a block-modular circuit. The vertical part of the frame is designed with longitudinal guides, on which various nodes and units of the studied hydraulic system can be mounted along both sides. In particular, it is planned to install a bevelon-type resonator connected to a flexible high-pressure hose with a metal braid with a flexible throttle and drain highway. In the longitudinal grooves of the lower part of the frame, an installation of various injection and adjusting equipment is provided.
Recommendations for the implementation of a method for diagnosing a technological process
In addition to the spectral composition of the oscillations of the RJ, and as a result, the oscillations of the hydrolynes walls is of interest to measure the overall level of vibrations. To study the hydrodynamic processes occurring in hydraulic systems of SDM, in particular, in the hydraulic systems of bulldozers based on the T-170M tractor, a general level of vibrations were measured at control points.
The measurements were carried out by the AR-40 vibroaclerometer, the signal from which the Vibrationanalizer SD-12M was received. The sensor was fastened on the outer surface of the hydrolynea wall using a metal bracket.
When measuring the overall level (OU) it was observed that at the time of the process of lifting or lowering the dump (at the time of stopping the hydraulic cylinders) the amplitude of the oscillations (peak) of the vibrating the walls of the hydrolynee wall increases sharply. This can be partially explained by the fact that at the moment of impact of the dump of land, as well as at the time of stopping the hydraulic cylinders when the dump is lifted, vibration is transmitted to the bulldozer as a whole, including the walls of hydrolynes.
However, one of the factors affecting the magnitude of the vibrating the walls of the hydrolynes walls can also be hydrate. When the bulldozer dumped during the rise reaching the extreme top position (or when lowering the land), the hydraulic cylinder rod with the piston also stop. The working fluid moving in the hydrolyanium, as well as in the rod cavity of the hydraulic cylinder (operating on the rise of the dump), meets the obstacle in its path, the power of the RH inertia is pressed on the piston, the pressure increases sharply, which leads to the appearance of the hydrowarder. In addition, from the moment when the piston of the hydraulic cylinder has already stopped, and until the moment when the fluid through the safety valve will go to the drain (until the safety valve is triggered), the pump continues to be injected into the working cavity, which also leads to an increase in pressure.
When conducting studies, it was determined that the amplitude of the vibrating the walls of the wall of pressure hydrolynas sharply increases both on the site directly adjacent to the pump (at a distance of about 30 cm from the latter) and on the site directly adjacent to the hydraulic cylinder. At the same time, the amplitude of vibration signs in the control points on the case of the bulldozer increased slightly. Measurements were carried out as follows. The bulldozer on the basis of the T170m tractor was located on the smooth concrete floor. The sensor was consistently fixed in the control points: 1 - point on the pressure hydrolyne (flexible hydrolynium) directly adjacent to the pump; 2 - point on the pump housing (on the fitting), located at a distance of 30 cm from point 1.
Measurements of the peak parameter were made during the rope raising process, and the first two or three averants were carried out in a state of idle operation of the pump, that is, when the duck hydraulic cylinder was at rest. When the dump approach and the value of the peak parameter began to increase. When the dump came to the extreme upper position, the peak parameter reached its maximum (Yaya / M-Maximum). After that, it was doped fixed in the extreme upper position, the peak parameter fell to the value he had at the beginning of the rise process, that is, when the pump was dried (TJ / minimum). The interval between adjacent measurements was 2.3 s.
When measuring the peak parameter at point 1 in the range from 5 to 500 Hz (Fig. 3.7.2) in a sample of six measurements, the medium-medium ratio of the peak maximum to the Yaya / M-minimum (PIKSHKS / PIKMT) is 2.07. With the standard deviation of the results O \u003d 0.15.
From the data obtained, it can be seen that the Q3 coefficient is 1.83 times more for point 1 than for point 2. Since points 1 and 2 are located at a short distance from each other, and the point 2 is rigidly connected to the pump housing than point 1, then Approve: Vibrations at point 1 are due to a large degree of pressure pulsations in the working fluid. And the maximum vibration at point 1, created at the time of stopping the dump, is due to a shock wave propagating from the hydraulic cylinder to the pump. If vibration at points 1 and 2 was due to mechanical oscillations arising at the time of the dump stop, the vibration at point 2 would be more.
Similar results were obtained and when measuring the facility parameter in the frequency range from 10 to 1000 Hz.
In addition, when conducting studies on a plot of pressure hydrolynan, directly adjacent to the hydraulic cylinder, it was determined that the overall level of vibrations of the hydrolyanium wall is much larger than the overall level of vibrations in the control points on the housing of the bulldozer, which is crammed, for example, at a short distance from the place of attachment of the hydraulic cylinder.
To prevent the occurrence of the hydroudar, it is recommended to install damping devices on the hydrolyanium area directly connected with the hydraulic cylinder, since the process of propagation of the hydrowater begins precisely from the working cavity of the latter, and then the shock wave extends throughout the hydraulic system, which can damage its elements. Fig. 3.7.2. The overall vibration level at the control point 1 (peak-5-500 Hz) Figure 3.7.3. The overall level of vibrations in the control point 2 (pump fitting) (peak-5 - 500 Hz) temporary pulsation diagrams of the outer surface of the wall of pressure hydrolynium in the process of lifting the dump of the DZ-171 bulldozer
A significant amount of information on dynamic processes in the working fluid can be measured by the parameters of its ripples in real time. Measurements were carried out during the lifting of the bulldozer dump from the rest of the rest of the upper position. Figure 3.7.4 shows a graph of the change in the vibrations of the outer surface of the wall of the pressure of the pressure hydrolynium directly adjacent to the NSh-100 pump, depending on the time. The initial portion of the graph (0 t 3 s) corresponds to the operation of the pump at idle. At the time of time T \u003d 3, the bulldozer switched the distributor knob to the "Podle" position. At that moment, there was a sharp increase in the amplitude of the vibrating the walls of the hydrolynee wall. And there was not a single impulse of a large amplitude, but a cycle of such pulses. Of the 32-obtained vibrations (on 10 different bulldozers of the said brand), there were 3 pulses of different amplitudes (the largest amplitude - in the second). The interval between the first and second impulse was less than the duration than the interval between the second and third (0.015 C against 0.026), that is, the total pulse duration is 0.041 p. On the chart, these impulses merge into one, because the time between two adjacent pulses is quite small. The average amplitude of the maximum value of the vibration resumption increased by an average of K \u003d 10.23 times compared with the average value of the vibration discharge during the operation of the pump at idle. The mean square error was Art \u003d 1.64. On similar graphs obtained by measuring the vibrations of the wall of the pump fitting, which connects the half-pressure cavity of the latter with the pressure line, such a sharp jump of vibrations is observed (Fig. 3.7.4), which can be explained by the rigidity of the walls of the fitting.
Kosolapov, Viktor Borisovich
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| Heating of the working fluid to a temperature of more than 60 ° C | On pipelines | - Low level working fluid in the tank Filters are clogged - Skorno Sapun |
| Heating pump | On the housing of the pump and adjacent nodes | - Low feed and, as a result, insufficient operational speed |
| Heating of hydraulic cylinders and hydromotors | On the housing of the hydraulic cylinder, hydromotor and the pipelines adjacent to them at a distance of 10-20 cm | - Faulty hydraulic cylinder (seal wear, piston damage) - Faulty hydraulic engine (wear of pistons and distributor, failure of bearings) |
| Heating hydraulic distributors | On the housing of the hydraulic distributor and adjacent pipelines of the discharge of the working fluid | - Faulty hydraulic distributor (shovers wear, valve faults) |
If, with the help of the senses, it was not possible to identify a malfunction, then it is necessary to use instruments: pressure gauges, flow meters, etc.
How to approach the search for more complex malfunctions of the hydraulic system?
Before starting troubleshooting, you need to clearly know which parameters of the hydraulic system must be measured to obtain information about the location of the fault, and with what special tools, devices and equipment do it.
Measured parameters
For the normal functioning of the machine to its working body, a certain force must be transferred (torque) at a certain speed and in a specific direction. The correspondence of these parameters is predetermined and should provide a hydraulic device that converts the hydraulic energy of the fluid flow into the mechanical energy of the output link. The correct work of the working body depends on the flow parameters - consumption, pressure and directions.
Consequently, to check the operation of the hydraulic system, you must check one or more of these parameters. To make a decision on which parameters it is necessary to check, you must obtain complete malfunctional information.
Often a malfunction message in the machine consists of rather inaccurate information, for example: "insufficient power". Power depends on both effort on the output link and from its speed, i.e. from two parameters. In this case, to make a decision on which parameter must be verified, more targeted questions should be set: the drive works too slowly or does it not develop the required effort or torque?
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After determining the essence of the fault (insufficient speed or force, the incorrect direction of movement of the working body) can be defined, the deviation of which flow parameter (consumption, pressure, directions) from the desired value led to this fault.
Although the procedure for finding a fault is based on controlling flow, pressure and flow direction, there are other system parameters that can be measured both in order to localize the faulty node and for definition of the causes of its malfunction:
- pressure at the entrance to the pump (Vacuummetric) - to determine the faults in suction lines;
- temperature - usually a higher temperature of one of the nodes of the system (compared to the temperature of the rest) is a faithful sign that the leak occurs;
- noise - with systematic and routine checks, noise is a good indicator of the state of the pump;
- pollution level - with a repeated appearance of the hydraulic system failures, it is necessary to check the contamination of the working fluid to determine the causes of the fault.
Source photo: site
Special devices, tools and equipment for the diagnosis of hydraulic systems
IN hydraulic system The pressure is usually measured by a pressure gauge or vacuum, and flow meter consumption. In addition, others may be useful for a diagnostic specialist devices and tools:
- pressure converter and checker - if the accuracy of pressure measurement should be higher than the accuracy that the pressure gauge provides, and also if it is necessary to measure the pressure during the transition process or under the action of reactive perturbations from the external load side (the pressure converter issues an alternating voltage depending on the applied pressure);
- a graded vessel and stopwatch - when measuring very low costs, such as leaks, with their help, it is possible to obtain greater accuracy than when measuring the flow meter;
- temperature sensor or thermometer - To measure the temperature in the hydraulic tank, you can set the temperature sensor (often combined with the operating fluid level indicator), and it is recommended to use the sensor outstanding alarm signal as soon as the temperature of the working fluid becomes too low or too high;
- thermocouple - to measure local temperature in the system;
- noise meter - Increased noise is also a clear sign of a system malfunction, especially for the pump. With the help of the noise meter, you can always compare the noise level of the "suspected" pump with the noise level of the new pump;
- particle counter - allows with a high degree of reliability to determine the level of pollution of the working fluid.
Diagnostics of the hydraulic system with a functional problem in the excavator
Step 1. Incorrect drive operation may have the following reasons.:
- speed executive mechanism does not match the specified;
- the supply of the working fluid of the actuator does not correspond to the specified;
- lack of movement of the actuator;
- movement in the wrong direction or uncontrolled traffic of the actuator;
- incorrect sequence of including actuators;
- "Creeping" mode, very slow work of the actuator.
Step 2. The hydraulic scheme is determined by the brand of each component of the system and its function
Step 3. Conscribe lists of nodes that may be the cause of the operation of the machine. For example, the insufficient velocity of the actuator actuator may be a consequence of an insufficient fluid consumption entering the hydraulic cylinder, or its pressure. Therefore, it is necessary to make a list of all nodes that affect these parameters.
Step 4. Based on a specific diagnostic experience, the priority procedure for checking nodes is determined.
Step 5. Each node contained in the list is pre-verified in accordance with the sequence. Check is carried out according to such parameters as proper installation, setting, signal perception, etc., in order to identify abnormal signs (as, for example, elevated temperature, noise, vibration, etc.)
Step 6. If, as a result of the preliminary check, the node that has a malfunction is not found, then a more intensive check of each node using additional tools is carried out without removing the node from the machine.
Step 7. Checking using additional devices should help find a faulty node, after which you can decide whether to repair it or replace it.
Step 8. Before re-starting the machine, it is necessary to analyze the causes and consequences of a malfunction.. If the problem is caused by contamination or an increase in the temperature of the hydraulic fluid, then it can be repeated. Accordingly, it is necessary to carry out further malfunctional measures. If the pump broke, then his wreckage could enter the system. Before connecting a new pump, the hydraulic system should be thoroughly rinsed.
* Think about what could damage, as well as the further consequences of this damage.
Excavators are designed to work with frozen or not soils, as well as with pre-crushed rock rocks. Temperature range of machinery - -40 ... + 40 ° C. The excavator device includes several nodes that ensure the operation of the machine.
As aggregates are classified
Excavators equipped with a working body with one bucket are divided into categories:
- On functional purpose. There are machines intended for construction work, special and career. The latter are equipped with a reinforced bucket designed to work with scaling rocks.
- According to the design of the chassis - wheeled on a special chassis, wheeled on a car chassis tracked. The latter can be equipped with tracked ribbons with an enlarged width.
- By the type of working body drive - hydraulic, electrical, combined.
How the excavator is arranged
The overall device of the excavator includes:
- running part;
- engine;
- hydraulic system;
- transmission;
- cabin with controls;
- platform with a rotary device;
- worker.
Engine mounted on the rotary platform internal combustion With ignition from compression. Motor has a liquid cooling system. Cooling fan drive automatic, but there is a forced switching key. To increase the power and reduce fuel consumption, the installation of turbocharger is applied. The engine drives the operating mechanisms of the excavator by means of a hydraulic or electrical transmission. Mechanical transmissions are applied on outdated techniques.
The swivel part is mounted on the chassis through a chassis, providing a 360 ° rotation. On the platform placed the operator cabin, hydraulic and electrical system, Arrow with drive and control mechanisms. Excavator boom can be equipped with buckets of various designs or grooves, which reduces the time required to create trenches. It is possible to install hydraulic hammers or other equipment necessary when conducting earthmoving work.
On mechanical drive excavators, winches are used, which directly control the movement of the arrows. The machines meet winches with 1 or 2 shafts. The 1st is considered a node that has a lifting and traction drums installed on a single shaft. If the drums of the winches are separated by shaft, then it is called a 2-wedal \u200b\u200bone. Such mechanisms are installed at large excavators.
The drive of the winches is performed by shafts through a gearbox or chain, carried out from the main shaft of the transmission. For inclusion, multi-disc friction clutches are used, for stopping - tape brakes. The cable is laid on the drum into one or more layers depending on the length.
The design of the mini-excavator does not differ from the principles laid out in full-size techniques. The difference is to simplify the structure of hydraulics and the use of small-sized diesel engine. The operator's workplace is located in a closed cabin equipped with ventilation and heating systems.
The device of the loader excavator differs from the above-described mechanism. The working bucket is located on the hinge arrows in the front of the standard wheel tractor. Loading equipment has hydraulic driveManufactured which is carried out from the operator's cab.
Hydraulic Excavator Class 330-3
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Brief introduction:
Measure the pressure setting of the main safety valve in the bulk channel of the main pump (the pressure of the main safety valve can also be measured using the DR.ZX diagnostic system.)
Preparation:
1. Turn off the engine.
2. Press the valve for the release of air located in the upper part of the hydraulician to reset the residual pressure.
3. Remove the fittings plug to check the pressure on the bulk channel of the main pump. Install the adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941).
: 6 mm
Connect the DR.ZX diagnostic system and select the monitor function.
4. Turn on the engine. Make sure that there is no visible leakage at the installation site.
5. Support the temperature of the working fluid in the range of 50 ± 5 ° C.
Measurement:
1. Measurement conditions are shown in the table below:
2. First of all, slowly move the levers of carpet management, handle and an arrow for a complete move and unload each contour.
3. With regard to the rotation function of the swivel, lock it in a stationary state. Unload the circuit of the rotation rotation mechanism, slowly moving the movement control lever.
4. With regard to the movement function, fix the caterpillars in front of a fixed object. Slowly moving the movement lever of the movement mechanism, unload the contour of the movement mechanism.
5. By pressing the digging mode switch, slowly move the levers of the bucket control, handle and an arrow for a complete move and unload each circuit for eight seconds.
Rating results:
Refer to the topic "Standard performance" in the T4-2 subsection.
Note: If the measured pressure values \u200b\u200bfor all functions below the values \u200b\u200bspecified in the specification, the likely cause can be a diagnosed value of the main safety valve adjustment. If the pressure open below the desired value is only for any single function, it is possible that the reason lies not in the main safety valve.
The procedure for adjusting the pressure setting of the main safety valve
Adjustment:
In the case of adjusting the setting pressure during digging operation in high power mode, adjust the pressure adjustment from the high pressure side of the main safety valve. In case of adjusting the tuning pressure during digging operation in normal power mode, adjust the pressure adjustment pressure low pressure Basic safety valve.
- Adjusting the pressure adjustment procedure for the main safety valve from the high pressure side
1. Loosen the lock nut (1). Tighten the plug (3) slightly while the stopper (3) does not touch the end of the piston (2). Tighten the lock nut (1).
: 27 mm
: Cork (3): 19.5 N · m (2 kgf · m), lock nut (1): 68 ... 78 N · m (7 ...
8 kgf · m) or less
2. Loosen the lock nut (4). Turning a plug (5), adjust the setting pressure in accordance with the specification data.
: 27 mm, 32 mm
: Stop nut (4): 78 ... 88 N · m (8 ... 9 kgf · m) or less
- Procedure for adjusting the pressure setting of the main safety valve from the low pressure side
1. Loosen the lock nut (1). Tube the plug (3) counterclockwise until the setup pressure becomes the corresponding specified in the specification. Tighten the lock nut (1).
: 27 mm, 32 mm
: Lock nut (1): 59 ... 68 N · m (6 ... 7 kgf · m) or less
2. At the end of the adjustment, check the installed pressure values.
Note: Standard setup pressure changes (reference values)
| The number of revolutions of the screw | 1/4 | 1/2 | 3/4 | 1 | |
| Value for changing the pressure of the safety valve: plug (5) (from an increased pressure) | MPa | 7,1 | 14,2 | 21,3 | 28,4 |
| (kgf / cm2) | 72,5 | 145 | 217,5 | 290 | |
| Value for changing the pressure of the safety valve: plug (3) (from low pressure) | MPa | 5,3 | 10,7 | 16 | 21,3 |
| (kgf / cm2) | 54 | 109 | 163 | 217 | |
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