CN-121993388-A - Fault identification and processing method and control system for high-pressure pump

CN121993388ACN 121993388 ACN121993388 ACN 121993388ACN-121993388-A

Abstract

The application provides a fault identification and processing method and a control system of a high-pressure pump, wherein the sensor assembly acquires operation information of the high-pressure pump and sends the operation information to an MCU, the MCU determines an operation state of the high-pressure pump according to the operation information, the operation state comprises a normal state, an idle state, a bubble state and a blocking state, the MCU sends a normal instruction or a control instruction to an ECU according to the operation state, and the ECU limits the high-pressure pump to operate or controls the high-pressure pump to stop according to the control instruction. The application avoids the dry grinding high heat of the motor in the state without liquid cooling, effectively controls the temperature rise of the motor, avoids insulation aging or coil burning, and remarkably prolongs the service life of the motor.

Inventors

Lv tengfei
CHEN ZHU
YANG YULIANG

Assignees

上海技涵电子科技有限公司

Dates

Publication Date: 20260508
Application Date: 20260228

Claims (10)

1. The fault identification and processing method for the high-pressure pump is characterized by being applied to a control system of the high-pressure pump, wherein the control system of the high-pressure pump comprises a sensor assembly, an MCU and an ECU, the sensor assembly is connected with the high-pressure pump, the MCU is connected with the sensor assembly and the ECU, the ECU is connected with the high-pressure pump, and the ECU enables the high-pressure pump to operate through a MOSFET for driving the high-pressure pump; The method comprises the following steps: the sensor assembly acquires the operation information of the high-pressure pump and sends the operation information to the MCU; The MCU determines the running state of the high-pressure pump according to the running information, wherein the running state comprises a normal state, an idle state, a bubble state and a blocking state; The MCU sends a normal instruction or a control instruction to the ECU according to the running state; the ECU limits the high-pressure pump to operate or controls the high-pressure pump to stop according to the control instruction.
2. The method for identifying and processing faults according to claim 1, wherein the operation information comprises one or more of voltage information, current actual measurement information, rotation speed actual measurement information, temperature information, working condition mode and high-frequency noise energy; wherein the voltage information is a voltage value of electric power received by the motor of the high-pressure pump at a plurality of time points within a preset time length; the current measured information is current values of electric power received by the motor of the high-pressure pump at a plurality of time points within the time length; the rotation speed actual measurement information is rotation speed values of the motor of the high-pressure pump at a plurality of time points within the time length; The temperature information is temperature values of the high-pressure pump at a plurality of time points within the time length; the working condition modes are running modes of a motor of the high-pressure pump, and comprise a continuous mode, an indirect mode and a pulse mode; the high frequency noise energy is the ratio of the sound wave energy which exceeds the sound wave energy in the preset bubble frequency range in the sound wave emitted by the high pressure pump in the time length.
3. The fault identification and handling method of claim 2, wherein the sensor assembly obtains operational information of the high pressure pump, comprising: a voltage sensor in the sensor assembly acquires a voltage value of the power received by the high-voltage pump to obtain voltage information; A current sensor in the sensor assembly acquires a current value of the power received by the high-voltage pump to obtain current actual measurement information; a rotating speed sensing module in the sensor assembly collects the rotating speed of a motor in the high-pressure pump to obtain rotating speed actual measurement information; A temperature sensor in the sensor assembly acquires the temperature of the high-pressure pump to obtain the temperature information; the working condition recognition module in the sensor assembly recognizes the operation working condition of the high-pressure pump, and the working condition mode is obtained; a sound sensor in the sensor assembly collects sound generated when the high-pressure pump operates, and the high-frequency noise energy is obtained; and summarizing one or more of the voltage information, the current actual measurement information, the rotating speed actual measurement information, the temperature information, the working condition mode and the high-frequency noise energy to obtain the operation information.
4. The fault identification and handling method according to claim 2, wherein the MCU determining the operating state of the high pressure pump from the operating information comprises: performing compensation operation on the current actual measurement information according to the voltage information and the voltage nominal information of the high-pressure pump to obtain current compensation information, and taking the current compensation information as the current information of the high-pressure pump; performing compensation operation on the rotation speed actual measurement information according to the voltage information and the voltage nominal information to obtain rotation speed compensation information, and taking the rotation speed compensation information as rotation speed information of the high-pressure pump; determining the current fluctuation rate of the high-pressure pump according to the current information; determining the rotational speed fluctuation rate of the high-pressure pump according to the rotational speed information; According to the temperature information, determining a temperature rise value of the high-pressure pump; and determining the running state of the high-pressure pump according to one or more of the current information, the rotating speed information, the current fluctuation rate, the rotating speed fluctuation rate, the high-frequency noise energy and the temperature rise value of the high-pressure pump based on a preset decision boundary.
5. The fault identification and handling method according to claim 4, wherein before the MCU determines the operating state of the high pressure pump based on threshold information and the operating information, the method comprises: The MCU determines a current threshold value of the high-pressure pump according to the temperature information and the working condition mode, wherein the current threshold value is an allowable current range of the high-pressure pump in one working condition mode; the MCU constructs a decision boundary of the high-pressure pump according to the current threshold, the rotating speed rated value of the motor of the high-pressure pump, the current rated value of the motor, the current fluctuation rate, the rotating speed fluctuation rate, the high-frequency noise energy and the temperature rise value of the test pump in a plurality of running states, wherein the test pump is the high-pressure pump with the same model as the high-pressure pump, and the decision boundary is used for determining running information corresponding to each running state.
6. The method according to claim 2, wherein the control command includes a record command, a limit command, a stop command, and an exhaust command; the MCU sends a normal instruction or a control instruction to the ECU according to the running state, and the method comprises the following steps: if the MCU determines that the running state is a normal state, a normal instruction is sent to the ECU; If the MCU determines that the running state is an idle state, calculating the idle confidence coefficient of the high-pressure pump according to the current actual measurement information and the rotating speed actual measurement information; The MCU sends one of a recording instruction, a limiting instruction and a stopping instruction to the ECU according to the no-load confidence coefficient; The MCU sends an exhaust instruction to the ECU if the running state is determined to be a bubble state; the MCU sends a shutdown instruction to the ECU if the running state is determined to be a blocking state; the method comprises the steps of recording an instruction, a high-pressure pump, a storage module, a high-pressure pump, a storage module, a limit instruction, a shutdown instruction and an exhaust instruction, wherein the recording instruction is used for indicating the ECU to send idle load recording data to the storage module, the idle load recording data records the times of the high-pressure pump in an idle load state, the limit instruction is used for indicating that the cleaning time of the high-pressure pump does not exceed preset limit time each time, the shutdown instruction is used for indicating the shutdown of the high-pressure pump, a fault code is further arranged in the shutdown instruction, and the exhaust instruction is used for indicating the opening of an exhaust valve of the high-pressure pump.
7. The method according to claim 6, wherein the MCU transmits one of a record instruction, a limit instruction, and a shutdown instruction to the ECU according to the no-load confidence level, comprising: the MCU sends the recording instruction to the ECU if the idle load confidence coefficient is determined to be larger than a first threshold value; The MCU sends the limiting instruction to the ECU if the idle load confidence coefficient is determined to be larger than a second threshold value; and if the MCU determines that the idle load confidence coefficient is greater than a third threshold value, the MCU sends the shutdown instruction to the ECU.
8. The fault identification and handling method according to claim 6, wherein the ECU limits the high pressure pump operation or controls the high pressure pump to stop according to the control instruction, comprising: If the ECU receives the recording instruction, generating no-load recording data according to the times of the received recording instruction, and storing the no-load recording data into the storage module; the ECU generates an alarm signal if the idle load record data exceeds a preset idle load threshold value; If the ECU receives the limiting instruction, analyzing limiting time from the limiting instruction, and driving the high-pressure pump according to the limiting time; If the ECU receives the shutdown instruction, a fault code in the shutdown instruction is analyzed, and the high-pressure pump is controlled to be shut down, wherein the fault code comprises a blocking fault code representing blocking and an idle fault code representing idle load; and if the ECU receives the exhaust instruction, outputting a high level or PWM signal with the exhaust time length being the exhaust time to an exhaust valve of the high-pressure pump so as to drive the exhaust valve to be in an opening state in the exhaust time.
9. The fault identification and handling method according to claim 1, wherein the ECU restricts the high pressure pump from operating or controls the high pressure pump to stop according to the control command, the method further comprising: and predicting the service life of the high-pressure pump according to the dead time and the bubble time, and obtaining the residual service life of the high-pressure pump, wherein the dead time is the dead time of the high-pressure pump from the time of starting to use to the current time, and the bubble time is the bubble time of the high-pressure pump from the time of starting to use to the current time, and is in a bubble state.
10. A control system for a high-pressure pump, characterized in that it is operated with a fault recognition and treatment method for a high-pressure pump according to any one of claims 1 to 9; the control system of the high-pressure pump comprises a sensor assembly, an MCU and an ECU, wherein the sensor assembly is connected with the high-pressure pump, the MCU is connected with the sensor assembly and the ECU, the ECU is connected with the high-pressure pump, and the ECU enables the high-pressure pump to operate through a MOSFET for driving the high-pressure pump; the sensor assembly is used for acquiring the operation information of the high-pressure pump and sending the operation information to the MCU; the MCU is used for determining the running state of the high-pressure pump according to the running information, wherein the running state comprises a normal state, an idle state, a bubble state and a blocking state; the MCU is also used for sending a normal instruction or a control instruction to the ECU according to the running state; the ECU is used for limiting the operation of the high-pressure pump or controlling the stopping of the high-pressure pump according to the control instruction.

Description

Fault identification and processing method and control system for high-pressure pump Technical Field The invention relates to the technical field of motors, in particular to a device for starting a motor or an electromechanical converter, and particularly relates to a fault identification and processing method and a control system of a high-pressure pump. Background A high pressure pump is a precision device capable of converting mechanical or other forms of energy into fluid pressure energy, thereby outputting far above standard atmospheric pressure. However, at present, whether liquid exists in the liquid tank can only be known, but whether the high-pressure pump is in an idle running state or not can not be known because of poor infusion pipelines or falling of the pipelines and other reasons, so that the conditions of overheating of a motor of the high-pressure pump, dry grinding damage of a mechanical seal, ineffective energy consumption and the like are caused. Disclosure of Invention The application provides a fault identification and processing method and a control system for a high-pressure pump, which are used for solving the problems that the prior art cannot know whether the hydraulic pump is in an idle state or not, so that the current high-pressure pump is easy to have idle running, and the motor of the high-pressure pump is overheated, the mechanical seal is damaged by dry grinding, the energy consumption is invalid and the like. The application provides a fault identification and processing method of a high-pressure pump, which is applied to a control system of the high-pressure pump, wherein the control system of the high-pressure pump comprises a sensor assembly, an MCU and an ECU, wherein the sensor assembly is connected with the high-pressure pump, the MCU is connected with the sensor assembly and the ECU, the ECU is connected with the high-pressure pump, and the ECU enables the high-pressure pump to operate through a MOSFET for driving the high-pressure pump; The method comprises the following steps: the sensor assembly acquires the operation information of the high-pressure pump and sends the operation information to the MCU; The MCU determines the running state of the high-pressure pump according to the running information, wherein the running state comprises a normal state, an idle state, a bubble state and a blocking state; The MCU sends a normal instruction or a control instruction to the ECU according to the running state; the ECU limits the high-pressure pump to operate or controls the high-pressure pump to stop according to the control instruction. In the scheme, the operation information comprises one or more of voltage information, current actual measurement information, rotation speed actual measurement information, temperature information, working condition mode and high-frequency noise energy; wherein the voltage information is a voltage value of electric power received by the motor of the high-pressure pump at a plurality of time points within a preset time length; the current measured information is current values of electric power received by the motor of the high-pressure pump at a plurality of time points within the time length; the rotation speed actual measurement information is rotation speed values of the motor of the high-pressure pump at a plurality of time points within the time length; The temperature information is temperature values of the high-pressure pump at a plurality of time points within the time length; the working condition modes are running modes of a motor of the high-pressure pump, and comprise a continuous mode, an indirect mode and a pulse mode; the high frequency noise energy is the ratio of the sound wave energy which exceeds the sound wave energy in the preset bubble frequency range in the sound wave emitted by the high pressure pump in the time length. In the above-mentioned scheme, the operation information of high-pressure pump is acquireed to the sensor assembly, includes: a voltage sensor in the sensor assembly acquires a voltage value of the power received by the high-voltage pump to obtain voltage information; A current sensor in the sensor assembly acquires a current value of the power received by the high-voltage pump to obtain current actual measurement information; a rotating speed sensing module in the sensor assembly collects the rotating speed of a motor in the high-pressure pump to obtain rotating speed actual measurement information; A temperature sensor in the sensor assembly acquires the temperature of the high-pressure pump to obtain the temperature information; the working condition recognition module in the sensor assembly recognizes the operation working condition of the high-pressure pump, and the working condition mode is obtained; a sound sensor in the sensor assembly collects sound generated when the high-pressure pump operates, and the high-frequency noise energy is obtained; and summarizing one or more of the volta