Built-in test technology for electro-hydraulic servo-valve amplifier
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摘要:
目的 电液伺服阀的工作环境恶劣、测试性设计欠缺，为了提高电液伺服阀的易用性和维修性，需开展机内测试设计。 方法 针对电液伺服阀内放大器的特点，提出一体化机内测试（BIT）方法，开展BIT软/硬件实现和防虚警措施的具体设计，并搭建闭环电液伺服系统进行验证。 结果 试验结果表明，该BIT设计方法可行，实现了在线、快速的故障检测功能。 结论 BIT方法是降低电液伺服系统全寿期维护成本的有效途径，具有一定的工程应用价值。 -
关键词:
- 电液伺服阀放大器 /
- 一体化机内测试(BIT) /
- 故障检测与隔离 /
- 故障码
Abstract:Objectives The electro-hydraulic servo valve operates in a harsh working environment but lacks integrated testability. In order to improve the usability and maintainability of electro-hydraulic servo valves, it is necessary to design a built-in test (BIT). Methods A BIT method involving the characteristics of the valve amplifier is proposed. On this basis, the implementation of BIT software/hardware and the concrete design of anti-false alarm measures are given, and a closed-loop electro-hydraulic servo system is constructed for verification. Results The verification test results show that this design method is feasible and can quickly detect faults online. Conclusions The BIT method is an effective way to reduce the maintenance cost of the electro-hydraulic servo system life cycle, giving it certain engineering application value. -
图 1 电液伺服阀放大器的系统原理图
Figure 1. System schematic diagram of electro-hydraulic servo-valve amplifier
图 2 电液伺服阀放大器的电路框图
Figure 2. Schematic diagram of electro-hydraulic servo-valve amplifier
图 3 放大器的信号输入电路图
Figure 3. Schematic diagram of the signal input circuit of the amplifier
图 5 电液伺服阀放大器的故障检测流程
Figure 5. Flow chart of the fault detect of the electro-hydraulic servo-valve amplifier
图 6 电液伺服阀放大器的故障隔离流程
Figure 6. Flow chart of the fault isolation of the electro-hydraulic servo-valve amplifier
图 7 电液伺服阀放大器的BIT电路图
Figure 7. Schematic diagram of BIT of the electro-hydraulic servo-valve amplifier
图 8 电液伺服阀放大器BIT的试验环境示意图
Figure 8. The schematic diagram of test environment for the electro-hydraulic servo-valve amplifier
表 1 伺服阀放大器的故障模式影响分析表
Table 1. Analysis table of failure mode effect of the servo-valve amplifier
故障码 故障模式名称 故障影响 故障检测方法 00-10-01.01 放大器双相PWM信号驱动的输出断相故障 伺服阀失控，油缸跑偏 检测输出PWM信号电流，以此测试输出断相故障 00-10-01.02 微处理器程序“跑飞”或死机故障 伺服阀控制信号输出未知的结果，伺服系统失控 检测微处理器的定时输出脉冲，以此测试微处理器是否正常运行 00-10-01.03 A/D转换信号错误故障 控制输出的解算错误，导致伺服阀控制偏差或失控 基于A/D转换器芯片的特点，在特定的通道施加固定电压，以此测试A/D转换电路的完好性 00-10-01.04 伺服阀先导阀的阀芯卡滞故障 伺服阀无法运动，伺服阀控制功能失效 检测伺服阀先导阀的阀芯位移电压，并通过算法确认是否卡滞 
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表 2 电液伺服阀放大器BIT验证试验的结果
Table 2. Result of BIT verification test of the electro-hydraulic servo-valve amplifier
故障模式 故障原因 试验手段 故障注入
成功判据检测
方法故障检测
成功判据故障是否
成功检测故障隔离
成功判据故障是否
成功隔离编码 名称 00-10-01.01 放大器双相PWM信号驱动的输出断相故障 1）放大器输出电路A相或B相通道器件断路；2）放大器面板的外部电缆接线断路 断开放大器与伺服阀之间的驱动连线 示波器检测到伺服阀电磁铁两端的PWM波形消失 BIT 单故障注入，伺服阀控制的油缸无运动 是 测试微处理器将故障码00-10-01.01发送至上位机 是 00-10-01.02 功能微处理器程序“跑飞”或死机故障 1）功能微处理器芯片故障；2）微处理器外部的看门狗电路故障 将微处理器的复位脚电平
拉低微处理器运行指示灯停止
闪烁BIT 单故障注入，微处理器与上位机通信的心跳信号消失 是 测试微处理器将故障码00-10-01.02发送至上位机 是 00-10-01.03 A/D转换电路输入信号错误故障 A/D转换芯片或外围电路故障 去除放大器电路板上的A/D芯片 上位机无法得到固定的5 V 电压值 BIT 单故障注入，上位机无法得到固定的5 V 电压值 是 测试微处理器将故障码00-10-01.03发送至上位机 是 00-10-01.04 伺服阀先导阀的阀芯卡滞故障 伺服阀先导阀内的金属碎屑导致卡滞 将伺服阀先导阀的阀芯位移电压接信号地 伺服阀先导阀的阀芯位移电压信号为0 V，且保持不变 BIT 单故障注入，伺服阀先导阀的阀芯位移电压信号不变 是 测试微处理器将故障码00-10-01.04发送至上位机 是
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