柴油發(fā)動(dòng)機(jī)工程機(jī)械檢測診斷技術(shù)

1、柴油發(fā)動(dòng)機(jī) 工程機(jī)械檢測診斷技術(shù)一、維修策略與狀態(tài)維修 工程機(jī)械的用戶或修理者，除了熟悉設(shè)備的原理、結(jié)構(gòu)、功能之外，還應(yīng)了解制造廠家的設(shè)計(jì)思想，采取同制造 廠家一致的維修策略。為了設(shè)備維修而采取的可靠性維修 （RCM） ，可用歐盟標(biāo)準(zhǔn) （EN13306） 表述。預(yù)防維修是按機(jī)械運(yùn)轉(zhuǎn)小時(shí)（或公里 ）或機(jī)械技術(shù)狀態(tài)進(jìn)行的有計(jì)劃維修，其中預(yù)定維修是按每工作250、500、1 000、2 000、4 000 h 進(jìn)行的強(qiáng)制性保養(yǎng)作業(yè)為主的預(yù)防維修，而狀態(tài)維修是按日常點(diǎn)檢、參數(shù)監(jiān)測及性能測試結(jié)果安排的預(yù)防維修。二、無接觸測試技術(shù)點(diǎn)檢就是一些簡單的檢查，為查明使用環(huán)境（油、水、氣 ）的劣化或查出潛在故障而

2、進(jìn)行的少、無拆卸零部件的檢查。小松公司早期推薦的點(diǎn)檢用儀器與工具有二三十種之多。圖 1 是成都小松檢測技術(shù)研究所通過優(yōu)選集成的調(diào)試維 修測試箱，其中采用了多種無接觸測試技術(shù)，如紅外測溫、失速測定、漏氣壓力測定等。1紅外測溫紅外測溫的優(yōu)點(diǎn)可從附表看出?？捎? 種方法使用紅外測溫儀：點(diǎn)測量、溫差測量、掃描測量。定點(diǎn)紅外測溫，如制動(dòng)系統(tǒng)。要檢查大型自卸車的制動(dòng)系統(tǒng)動(dòng)力分配是否適當(dāng)，需要車輛直線行駛，制動(dòng)停止 后，立刻測量轉(zhuǎn)子或制動(dòng)鼓溫度。如果轉(zhuǎn)子和制動(dòng)鼓溫度有明顯變化，制動(dòng)鉗可能會(huì)被黏住或被拖移，從而導(dǎo)致制動(dòng) 力分配不當(dāng)。車輛行駛一段距離后檢測磨損的制動(dòng)蹄或失效的車輪軸承，若溫度明顯比環(huán)境溫度高，則

3、預(yù)示磨損過 多。溫差測量，利用紅外測溫儀測量的相對誤差極小、重復(fù)性好的特點(diǎn)，一般工程機(jī)械的冷卻水散熱器t在36 C時(shí)，冷卻系統(tǒng)的熱平衡正常。如果用紅外測溫儀測出t小于3 C,推測故障原因是節(jié)溫器未打開、水泵運(yùn)轉(zhuǎn)不良、風(fēng)扇膠帶松弛，水散熱器芯子堵塞等散熱不良所致；如果測出厶t大于6 C,原因是發(fā)動(dòng)機(jī)過熱。利用溫差測量還可判斷液壓油高溫等許多故障。紅外掃描測量，用于電氣柜元件的觸點(diǎn)、線圈的檢測，通過查找熱點(diǎn)確定故障點(diǎn)。檢測空調(diào)系統(tǒng)時(shí)，紅外測溫也 很有效。2失速測定利用機(jī)載轉(zhuǎn)速表、頻閃儀、光電轉(zhuǎn)速表等測定失速轉(zhuǎn)速（液壓失速、變矩器失速、全失速），可以很方便地判斷機(jī)械動(dòng)力不足的原因在發(fā)動(dòng)機(jī)還是在液壓系

4、統(tǒng)，或是在傳動(dòng)系統(tǒng)。與無負(fù)荷測功不同，發(fā)動(dòng)機(jī)失速測定，是利用機(jī)械本身的動(dòng)力傳動(dòng)系統(tǒng)，對發(fā)動(dòng)機(jī)加載荷，測試某些特定轉(zhuǎn)矩下 發(fā)動(dòng)機(jī)轉(zhuǎn)速由最高空轉(zhuǎn)轉(zhuǎn)速下降的程度，評價(jià)發(fā)動(dòng)機(jī)的性能（輸出功率 ）。在這個(gè)特定轉(zhuǎn)矩作用下，發(fā)動(dòng)機(jī)由最高空轉(zhuǎn)轉(zhuǎn)速下降而能維持穩(wěn)定運(yùn)轉(zhuǎn)的轉(zhuǎn)速，即所謂失速轉(zhuǎn)速。在液壓挖掘機(jī)發(fā)動(dòng)機(jī)外特性曲線上，失速轉(zhuǎn)速等同額定轉(zhuǎn)速。在推土機(jī)發(fā)動(dòng)機(jī)外特性曲線上，失速轉(zhuǎn)速通常介于 額定轉(zhuǎn)速與最大轉(zhuǎn)矩轉(zhuǎn)速之間?？ㄌ乇死展竞托∷晒旧a(chǎn)的挖掘機(jī)、推土機(jī)、裝載機(jī)，技術(shù)手冊上都有失速轉(zhuǎn)速 的基準(zhǔn)值和限度值。以推土機(jī)為例，當(dāng)實(shí)測變矩器失速轉(zhuǎn)速高于限度值上限時(shí)，推測故障原因是傳動(dòng)系統(tǒng)不良（如動(dòng)力換擋變矩器摩擦片打

5、滑 ）、變矩器吸空；當(dāng)實(shí)測變矩器失速轉(zhuǎn)速低于限度值下限時(shí)，推測故障原因是發(fā)動(dòng)機(jī)輸出功率不足、變矩器性能 不良 （進(jìn)出口壓力或鎖止離合器壓力不正常、內(nèi)泄漏過大）、液壓泵空載損失大等。3漏氣壓力測定利用漏氣測定儀檢查發(fā)動(dòng)機(jī)曲軸箱竄氣流量，可以判定氣缸-活塞 -活塞環(huán)組件的磨損狀況。小松、卡特彼勒及美康發(fā)動(dòng)機(jī)都提供有漏氣基準(zhǔn)值。三、在線監(jiān)測與故障診斷一體化技術(shù) 隨著工程機(jī)械廣泛應(yīng)用電子控制與信息處理技術(shù)，安裝了大量高可靠性傳感器，直接監(jiān)測各部運(yùn)行狀態(tài)的特征參 數(shù)，同時(shí)通過機(jī)載電腦處理后顯示故障類別或故障部位，供維修人員輔助故障診斷。1內(nèi)置自診斷系統(tǒng) 在小松、神鋼、大宇、現(xiàn)代等公司的液壓挖掘機(jī)上，都設(shè)

6、計(jì)有自診斷系統(tǒng)。利用嵌入式芯片在線監(jiān)測進(jìn)行故障診 斷的好處是：能及時(shí)發(fā)現(xiàn)機(jī)電系統(tǒng)隱患和記錄故障形成歷程；可自動(dòng)區(qū)分機(jī)電液一體化系統(tǒng)的故障類別，判斷故障起因于何種子系統(tǒng)（發(fā)動(dòng)機(jī)系統(tǒng)、電子系統(tǒng)、液壓系統(tǒng)），迅速進(jìn)行故障定位（故障部位、部件）；能減少人為診斷時(shí)間，及時(shí)進(jìn)行故障處理。利用自診斷系統(tǒng)以顯示故障歷程、故障代碼。根據(jù)故障代碼提示的相關(guān)電路，進(jìn)一步診斷傳感器、接插件、電磁 閥等故障點(diǎn)。自診斷系統(tǒng)提供的是一種輔助診斷方法，而且主要是與電氣電子、系統(tǒng)有關(guān)的故障。對于液壓系統(tǒng)本身（未顯示代碼 ）的大量故障可參照維修手冊提示的程序，進(jìn)一步檢查與液壓泵、閥、液壓馬達(dá)及附件有關(guān)的故障。2專用電子診斷裝置（

7、1）卡特彼勒公司的 ET在卡特彼勒 3126B 型發(fā)動(dòng)機(jī)上，采用了 HEUT（ 液壓作用電控單體噴油器 ）燃油系統(tǒng) HI3000 ，配之以 ADEM2000 電 控系統(tǒng)。當(dāng)發(fā)動(dòng)機(jī)出現(xiàn)功率下降、燃油耗增大、噪聲增大或故障指示燈點(diǎn)亮?xí)r，就要進(jìn)行故障診斷。利用卡特彼勒公司提 供的ET（電子技師），將其接到電控模塊旁的數(shù)據(jù)連接診斷插座上，就可以進(jìn)行電磁閥、驅(qū)動(dòng)壓力和斷缸的測試等，進(jìn) 行故障排查。（2）日立建機(jī)的 Dr.EX現(xiàn)在日立公司提供的故障診斷工具 Dr.EX（電腦醫(yī)生）是一臺裝有診斷軟件的掌上電腦。將 Dr.EX接到MC（主控制 器）或ICX（信息控制器）的插座上，就可以自診斷，以故障代碼形式指

8、示控制器和傳感器是否正常。此外，Dr.EX還有3 種監(jiān)控模式，顯示設(shè)定學(xué)習(xí)功能的數(shù)值，調(diào)整發(fā)動(dòng)機(jī)轉(zhuǎn)速、泵輸出流量及電液比例閥輸出的二次油壓等。（3）筆記本電腦在沃爾沃裝載機(jī)上設(shè)計(jì)有 MATRIS（機(jī)器跟蹤信息系統(tǒng)），在電控單元（ECU）中的油溫、水溫、制動(dòng)壓力以及發(fā)動(dòng)機(jī) 轉(zhuǎn)速等數(shù)據(jù)，都可通過連接到駕駛室內(nèi)診斷插座上的標(biāo)準(zhǔn)筆記本電腦顯示或打印出來。變速器離合器壓力過低時(shí)，可 根據(jù)報(bào)警記錄，分析離合器密封環(huán)磨損是否加快，以便備料檢修。四、遠(yuǎn)程測試與管理信息一體化技術(shù)工程機(jī)械走向“機(jī)電液一體化”，而信息化的重要組成部分是應(yīng)用遠(yuǎn)程監(jiān)控系統(tǒng)，實(shí)現(xiàn)自動(dòng)化、集成化的管理。遠(yuǎn)程監(jiān)控系統(tǒng)利用機(jī)載終端，對工程機(jī)械

9、運(yùn)行中的技術(shù)狀態(tài)和管理信息（地理位置、施工進(jìn)度等 ）進(jìn)行監(jiān)測。通過通信網(wǎng)絡(luò)，由遠(yuǎn)程監(jiān)控服務(wù)中心向終端用戶或技術(shù)服務(wù)商提供狀態(tài)檢測、故障診斷等服務(wù)。2004 年，小松公司推出了 KOMTRAX（ 康查士 ）系統(tǒng)。通過安裝在機(jī)械上的終端裝置（傳感器、嵌入式微處理器等），利用GPS（全球定位系統(tǒng)），在發(fā)送設(shè)備地理信息的同時(shí)，可將運(yùn)轉(zhuǎn)小時(shí)數(shù)、發(fā)動(dòng)機(jī)運(yùn)轉(zhuǎn)參數(shù)、液壓壓力等工況參 數(shù)，由地面天線發(fā)送后經(jīng)電信數(shù)據(jù)中心和小松的網(wǎng)絡(luò)服務(wù)器，傳輸?shù)较嚓P(guān)的計(jì)算機(jī)終端，供用戶或代理店使用?？挡槭肯到y(tǒng)的一個(gè)不足是目前還不能采用GPRS技術(shù)，GPRS（通用分組無線業(yè)務(wù)）能高速處理數(shù)據(jù)，可利用手機(jī)上網(wǎng)，省時(shí)、省力、省費(fèi)用。機(jī)

10、載終端由ARM嵌入式微處理器、GPS模塊、GPRS模塊等組成。ARM處理器通過 CAN（控制局域網(wǎng)）總線與機(jī) 器上的多個(gè)智能傳感器通信。這些傳感器采集各種運(yùn)行參數(shù)，如發(fā)動(dòng)機(jī)油壓、水溫、變速油壓、制動(dòng)壓力及液壓油溫 度等數(shù)據(jù)。 CAN 總線技術(shù)，支持分布式控制和實(shí)時(shí)控制的串行通信網(wǎng)絡(luò)，抗干擾性強(qiáng)，使用可靠。GPS模塊用于獲得當(dāng)前的地理位置信息。JTAG 接口用于在線編程和對內(nèi)部節(jié)點(diǎn)進(jìn)行測試。GSM（短信通信平臺）或GPRS（手機(jī)上網(wǎng)）模塊，通過通信網(wǎng)絡(luò)，“按時(shí)”（如每隔1h發(fā)送1次）或“按需”（當(dāng)監(jiān)控中心有呼叫請求或有故障報(bào)告時(shí) ）傳達(dá)到監(jiān)控服務(wù)中心，由監(jiān)控中心對機(jī)器運(yùn)行狀態(tài)實(shí)現(xiàn)遠(yuǎn)程監(jiān)控。遠(yuǎn)程監(jiān)

11、控服務(wù)中心將接收的故障診斷或狀態(tài)監(jiān)測的信息進(jìn)行記錄整理，提取參數(shù)的特征值與標(biāo)準(zhǔn)知識庫中的標(biāo)準(zhǔn) 值進(jìn)行比較，就可以供工程師進(jìn)行遠(yuǎn)程診斷，指導(dǎo)現(xiàn)場員工及時(shí)排除故障，減少停工損失。五、液壓測試技術(shù)與機(jī)電系統(tǒng)相比，液壓系統(tǒng)的狀態(tài)監(jiān)測和故障診斷的難度要大得多。液壓系統(tǒng)能量損耗，如P （壓力損失）、Q（流量損失）及厶T （溫度損失），反映了液壓能傳遞過程的控制特性。要測量壓力 （P ）和流量（Q ），并不像電路 中測量電壓 （V） 和電流 （ I ）那樣方便。如果推測液壓元件有無問題，把元件從機(jī)器上拆下來裝到液壓實(shí)驗(yàn)臺上檢測并不是一個(gè)好方法，因?yàn)檫@會(huì)割裂原 來的機(jī)電液一體化系統(tǒng)，不但構(gòu)建測試控制條件比較困

12、難，安裝也很麻煩。采用便攜式液壓測試儀，很方便。在一個(gè)檢測點(diǎn)可同時(shí)測定流量、壓力及溫度。變換測試儀在被測試機(jī)器的液壓系統(tǒng)中的串聯(lián)或并聯(lián)的位置，既能測試能源元件(液壓泵 )的性能，也能測試執(zhí)行元件(液壓馬達(dá)、液壓缸 )和控制元件(溢流閥、換向閥等 ) 的性能，能迅速查找出故障部位。泵測試，用于檢測液壓泵的性能。針對液壓挖掘機(jī)主泵的負(fù)(正 )流量控制或負(fù)荷傳感控制等不同的控制策略，有不同的伺服控制方式，詳見成都小松檢測技術(shù)研究所編寫的便攜式液壓測試儀用戶應(yīng)用方案匯編。在線測試，是查找液壓馬達(dá)、液壓缸及過載閥的附加實(shí)驗(yàn)，具體測試方法可參見成都小松檢測技術(shù)研究所編寫的 便攜式液壓測試儀用戶手冊。T 測

13、試，用于檢查整個(gè)液壓系統(tǒng)。將控制閥置于不同的部位，可以測出各換向閥子回路的總泄漏量，然后再斷開 該回路上不同元件的油路，可計(jì)算出相應(yīng)的內(nèi)泄漏量。六、虛擬儀器技術(shù)早期的檢測儀器是單臺的專用型儀器。從上世紀(jì) 80 年代的機(jī)架式到 90 年代的卡式儀器，這些積木型的臺式儀器 可稱為第二代儀器。第三代組合式儀器，被稱為虛擬化儀器，采用軟件作支撐平臺。所謂虛擬儀器是一套具有虛擬面板的計(jì)算機(jī)系統(tǒng)，借助鍵盤、鼠標(biāo)、觸摸屏，對計(jì)算機(jī)屏幕上的開關(guān)、按鈕進(jìn)行 操作，就能控制儀器的運(yùn)行，進(jìn)行數(shù)據(jù)的采集、顯示、存儲與分析。虛擬儀器的基礎(chǔ)是計(jì)算機(jī)系統(tǒng)，核心是軟件。 NI 公司的著名口號是：“軟件就是儀器”。推出虛擬儀器

14、系統(tǒng)的國外公司有HP(惠普)、Nl(國家儀器)等，國內(nèi)有哈工大的儀器王電子公司等。 虛擬儀器的優(yōu)點(diǎn)是適應(yīng)了儀器多品種的擴(kuò)展性要求，精度高、實(shí)時(shí)性好、入機(jī)界面好。 圖 2 所示為成都小松檢測技術(shù)研究所銷售的檢測系統(tǒng)傳感器組通過USB( 通用串行總線 )接口接到筆記本電腦上，應(yīng)用程序可用不同的工程單位顯示液壓參數(shù)的測量值。實(shí)時(shí)的圖形化界面或數(shù)字界面提供流量、壓力、溫度參數(shù)的瞬 時(shí)讀數(shù)和變動(dòng)趨勢。這種系統(tǒng)的顯著特點(diǎn)是：(1) 傳感器由計(jì)算機(jī)的 USB 接口供電，無需電池或外接電源；(2) 省卻了數(shù)據(jù)采集卡，降低了成本；傳感器米樣頻率可調(diào)，最咼可以每100 s米樣一次，即米樣頻率10 000 Hz。因

15、此系統(tǒng)可捕捉到有害的快速瞬變的壓力脈沖并顯示峰值壓力；(4) 可由用戶設(shè)置報(bào)警值，讀取或記錄“超量程”的讀數(shù)；這種雙向測試儀的量程可選配，最大流量750 L/min、壓力40 MPa、溫度150 C。Diesel engines, construction machinery detection and diagnosis technologyA maintenance strategy and state of repairThe user or repairer of construction machinery, in addition to the familiar principle

16、, structure, function, should also be aware of the manufacturers design ideas, consistent with the manufacturers maintenance strategy.For equipment maintenanceand reliability maintenance (RCM), available to EU standards (EN13306) statements.Preventive maintenanceis carried out by machinery operating

17、 hours (or kilometers) or mechanical state in aplanned maintenance, including scheduled maintenance is a mandatory maintenance jobs per work 250,500,1 000,2 000,4 000 h based preventive maintenance, and state maintenance is preventive maintenance arrangementsfor the daily spot check, parameter monit

18、oring and performance test results. Second, non-contact test technologyPoint inspection are some simple checks to identify the deterioration of the environment (oil, water, gas) or to detect potential failures and less demolition of parts of the check.Komatsu recommended early point inspection instr

19、uments and tools, as many as thirty kinds. Figure 1 Chengdu lnstitute of Komatsu detection technology throughthe optimization of integrated debugging maintenance tests box, which employs a variety of non-contact testing technology, such as infrared thermometry stall determination of leak pressure me

20、asurement.A. lnfrared Temperature MeasurementThe advantages of infrared temperature measurement can be seen from the Schedule. Using the infrared thermometer available 3 ways: point measurement, temperature measurement, scan measurement.Fixed-point temperature measurement, such as the braking system

21、. To check the brake system of a large dump truck power distribution whether it is appropriate to the vehicle goes straight brake to stop immediately after the measurement of the rotor or brake drum temperature. lf there are significant changes in the temperature of the rotorand brake drum, brake ca

22、liper may be stick or dragged shift, resultingin a misallocation of braking force. Detectvehicles traveling some distance, brakeshoe wear or failure of wheel bearings, if thetemperature is significantlyhigher than the ambient temperature, indicates excessive wear and tear. The difference in temperat

23、ure measurement using infrared thermometer to measure the relative error is very small, reproducible characteristics, general engineering machinery cooling water radiator t 3 6 C, the cooling systems heat balance and normal. Infrared thermometer measured t less than 3C,speculated that the causeof th

24、e malfunction thermostat is not open dysfunctional pump, fan, tape slack water radiator wick clogging cooling efficiency due 。 measured t greater than 6C,because of engine overheating. Temperature measurement canalso determine the hydraulic oil and high temperature failure. The infrared scan measure

25、ment of the electrical cabinet components for the detection of contacts, coils, through to find the hot spots to determine the point of failure. Detection of air-conditioning systems, infrared temperature measurement is also very effective. Two. Stall determination Use of airborne tachometer, strobo

26、scope, photoelectric tachometer etc. for the determination of the stall speed (hydraulic stall torque converter stall and full stall), you can easily determine the mechanical power of reason in the engine and hydraulic system, or in transmission.With no load dynamometer, engine stall determination i

27、s the use of the powertrain of the machinery itself, plus the engine load, to test the extent of certain torque, engine speed from the highest idling speed decreases, the evaluation of engine performance (power output) . In the role of this specific torque, the engine fell from the highest idling sp

28、eed to maintain the stable operation of the speed, the so-called stall speed.In the characteristic curve on the hydraulic excavator engine stall speed is equivalent to the rated speed. In the external characteristic curve of the bulldozer engine, stall speed is usually between rated speed and maximu

29、m torque and speed. Have a stall speed of the reference value and the limit value in the production of Caterpillar Inc. and Komatsu excavators, bulldozers, loaders, technical manuals.To bulldozers, for example, when the measured torque converter stall speed is higher than the limit value limit, sugg

30、esting that the cause of the malfunction is the transmission bad (such as a power shift torque converter friction plate skid), the torque converter suction air。 when measured torque converter The stallspeed is below the limit value limit, suggesting that the cause of the malfunction engine output, t

31、orque converter bad performance (import and export pressure or lock-up clutch pressure is not normal,internal leakage is too large),hydraulic pump no-load losses.3. Determination of leak pressureLeak determination of the instrument to check the engine crankcase blowby flow, can determine the state o

32、f wear of the cylinder- piston - piston ring components.Komatsu, Caterpillar and the United States and Hong engine leak baseline values. Online monitoring and fault diagnosis integrated technologyWith the extensive application of engineering machinery, electronic control and information processing t

33、echnology, the installation of a large number of high reliability sensors, direct monitoring of the characteristic parameters of the ministries operating status through the onboard computer processing fault type or fault position for maintenance staff assisted fault diagnosis .A. Built-in self-diagn

34、ostic systemHydraulic excavator Komatsu, Kobelco, Daewoo, Hyundai and other companies, are designed with self-diagnostic system. The benefits of using embedded chip line monitoring, fault diagnosis is: (1) the formation history of timely detection of hidden and record failure of electromechanical sy

35、stems 。 2 can automatically distinguish between categories of failure of hydraulic integration system, determine the fault caused by what subsystem (engine system electronic systems, hydraulic systems), rapid fault location (fault location, components)。 (3) can reduce the human time to diagnosis,tim

36、ely troubleshooting.Self-diagnostic system to show the fault history, fault code. The relevant circuit fault code prompt further diagnostic sensors, connectors, solenoid valve failure point.Self-diagnostic system to provide a complementary diagnostic methods, and mainly related to electrical and ele

37、ctronic, the system failure. Hydraulic system (not shown large number of failures of the code) refer to the program, prompted by the maintenance manual for further examination and failure of the hydraulic pumps, valves, hydraulic motors and accessories.Two. Special electronic diagnostic devices(1) C

38、aterpillar ETCaterpillar 3126B engines, the HI3000 of HEUT (hydraulic role of the Electronic Unit Injector) fuel system, combined with electronic control system to ADEM2000.When the engine power loss, fuel consumption increases, noise increases or the fault indicator is lit, it is necessary for faul

39、t diagnosis. Caterpillar ET (electronics technician), it receives a data connection on the diagnostic socket next to the electronic control module, solenoid valves, pressure-driven and off-cylinder test can be carried out for troubleshooting.(2) Hitachi Construction Machinery Dr.EXTroubleshooting to

40、ols provided by the Hitachi Dr.EX (PC Doctor) is a handheld computer with diagnostic software. Will Dr.EX received MC (master controller), ICX (information controller) socket on the self-diagnostic fault code indicates the controller and the sensor is normal. In addition, Dr.EX there are three kinds

41、 of monitor mode, set the value of the learning function, adjust the engine speed, the pump output flow and electro-hydraulic proportional valve output secondary hydraulic(3) notebook computerVolvo loader design MATRIS (machine tracking information system), electronic control unit (ECU), oil tempera

42、ture, water temperature, brake pressure and engine speed data, can be connected to the driving room on the diagnostic socket standard notebook display or print them out. Transmission clutch pressure is too low, according to police records, the analysis of clutch sealing ring wear is accelerated, so

43、that preparation overhaul. Fourth, remote testing and management of information integration technologyConstruction machinery to the hydraulic integration, information technology an important part of the application of remote monitoring systems, automated, integrated management.Remote monitoring syst

44、em using on-board terminals, and monitoring the technical state of construction machinery operation and management information (location, construction progress, etc.). State detection, fault diagnosis and otherservices provided to end users or technical service provider through the communication net

45、work from the remote monitoring service center.In 2004, Komatsu launchedKOMTRAX (Kang Charles River) system. Terminal devices(sensors, embedded microprocessors, etc.), the use of GPS (Global Positioning System) installed in the machinery, while sending equipment, geographic information, can be runni

46、ng the number of hours of engine operating parameters, hydraulic pressure working parameters sent by ground antennas, telecommunications data center and Komatsus network server, transfer to the computer terminal, for users or distributors use.Kang Charles River system is the lack of yet can not use

47、GPRS technology, GPRS (General Packet Radio Service) high-speed processing of data, you can use the mobile Internet, provincial, effort, costs. Airborne terminal by the composition of the ARM embedded microprocessor, GPS module, GPRS module. ARM processor through CAN (Control Area Network) bus on th

48、e machine and smart sensor communication. These sensors capture a variety of operating parameters such as engine oil pressure, water temperature, transmission oil pressure, brake pressure andhydraulic oil temperature data. CAN bustechnology, support for distributed controland real-time control of th

49、e serial communications network, the interference is strong, and reliable to use. The GPS module used to obtain current location information. JTAG interface for programming and test the internal nodes. GSM (SMS communication platform) or GPRS (mobile Internet) module via the communication network, t

50、ime (eg, every 1h send 1) or on demand (when the monitoring center call request or fault report) is communicated to monitoring service center, remote monitoring by the monitoring center of the machine operating status. Fault diagnosis or condition monitoring, remote monitoring service center will re

51、ceive information documenting eigenvalue extraction parameters and standards Knowledge of standard value, it can be for engineers to remotely diagnose and guide field staff to troubleshoot, to reduce downtime losses.5, hydraulic testing technology Compared with the mechanical and electrical system,

52、hydraulic system status monitoring and fault diagnosis much more difficult to The energy loss of the hydraulic system, such as P (pressure loss), Q (loss of flow), and T(temperature loss), reflecting the control characteristics of the hydraulic energy transfer process. To measure the pressure (P) an

53、d flow rate (Q), is not as easy as circuit to measure voltage (V) and current (I). Speculate whether of the hydraulic components, the components removed from the machine fitted to the hydraulic test bench testing is not a good method, because this will split the original hydraulic integrated system,

54、 not only to build the test more difficult to control conditions, the installation also a lot of trouble. Portable hydraulic tester, very convenient. Flow, pressure and temperature can be determined simultaneously in a detection point. Transform the location of the tester in the hydraulic system of

55、the machine being tested in series orin parallel, both to test the performance of the energy components (hydraulic pump), can also test actuator (hydraulic motors, hydraulic cylinders) and control components (relief, the performance of the valve and so on), can quickly find out the fault location. P

56、ump test for detection of pump performance. Compilation of the main pump for the hydraulic excavator negative (positive) flow control or load sensing control, different control strategies, different servo control, see the portable hydraulic tester user application program written by the Chengdu Koma

57、tsu detection Institute . Online test to find the hydraulic motor, hydraulic cylinder and contained an additional valve test, specific test methods can be found in the portable hydraulic tester user manual written by the Chengdu Komatsu detection Institute.T-test used to check the entire hydraulic s

58、ystem. Will be placed in different parts of the control valve, can measure the total leakage of the valve sub-loop, and then disconnect the fuel lines of the different components of the loop, calculate the corresponding internal leakage.Six, the virtual instrument technology Early detection instrument is a single dedicated instrument. From the rack of the 1980s to the 1990s cassette apparatus, a desktop instrument of these bu