Research On The Condition Monitoring And Fault Diagnosis Of The Welder's Hydraulic Control System

The hydraulic control system of the flash welding machine is the core of achieving its welding technology, and is the key of ensuring the band steel's welding quality .Because this hydraulic control system is the mechanical, electrical and hydraulic integrated system whose structure is complex and precision is high, its possible faults are not only structural, but also parametric ,it is difficultly timely and precise to locate and eliminate faults by artificial fault diagnosis methods. So it is crying to develop a suit of condition monitoring and fault diagnosis system, monitoring its states in real time and diagnosing its possible faults rapidly.In this paper, it studies the condition monitoring and fault diagnosis technologies of the hydraulic control system of the flash welding machine, combining sensor technology, technology of data acquisition and processing, computer technology, and technology of data base and fuzzy fault diagnosis theory, on the basis of summarizing relevant literature at home and abroad.First, it summarizes the history, the current situation and the development trend of the condition monitoring and fault diagnosis technologies of the hydraulic system, has determined the contents of the research by combining the characteristics of the hydraulic control system of the flash welding machine; Second, it analyzes the operation principles of the flash welding machine and its hydraulic systems, researches the common and individual faults of the hydraulic control system of the flash welding machine and their mechanism, laying the foundation for its fault diagnosis; Third, it determines the needed-to-monitor state parameters by analyzing the actual running status and working condition of the hydraulic control system of the flash welding machine. It develops the software and hardware of the condition monitoring and fault diagnosis system of the hydraulic control system of the flash welding machine, the system hardware is made up of the three modules of the signal pickup, the signal pre-processing and the acquisition of signal and shielded cable is used to communicate between them. The system software is made up of the seven modules of the signal acquisition and processing, the system parameter setting, the real-time display and alarm of signals, the real-time waveform display of signals, the database management, the data report and the fault diagnosis. It has built the whole condition monitoring and fault diagnosis technologies of the hydraulic control system of the flash welding machine; In the last, it researches the fuzzy fault diagnosis algorithm, applying it to the fault diagnosis of the system, on the basis of analyzing the relations between the symptom and the cause of faults of the hydraulic control system of the flash welding machineTheir results indicate the design Solutions and the implementation techniques of this system are correct, the system functions are perfect, the system performances are stable, by testing the functions and the performances of the condition monitoring and fault diagnosis technologies of the hydraulic control system of the flash welding machine, and after the more than six-month actual production run.