Design of low-power test platform for reversing characteristics of mine solenoid pilot valve
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摘要: 电磁先导阀是综采工作面实现无人化开采的核心元部件之一，目前矿用电磁先导阀测试方法多采用乳化液泵作为液源，功耗较大，此外，系统压力调节多采用手动调节方式，效率低。针对上述问题，设计了一种矿用电磁先导阀换向特性低功耗测试平台。该平台包括液压系统和测控系统2个部分。液压系统主要包括电气比例阀、气液增压泵、被试阀、蓄能器等部件，采用双头气液增压泵作为液源，以降低能耗；采用电气比例阀调节气液增压泵入口气压，将被试阀入口压力调节至所需值，实现系统压力自动调节。测控系统包括上位机、采集卡、程控电源、电气比例阀控制器（PID控制器）、多种传感器等，根据传感器安装和精度要求，选用激光位移传感器测试电磁铁顶杆位移，并采用PID控制器调节电磁先导阀进液口的压力。该平台可实现电磁先导阀换向过程中各项性能指标的实时动态监测和数据存储，包括电压、电流、进出口压力、顶杆位移、动态响应时间和实时功耗等，最大功率仅为800 W，提升了测试安全性和效率，大幅度降低了系统能耗，为研究人员提供了高效、可靠的测试和验证手段。Abstract: The electromagnetic pilot valve is one of the core components for realizing unmanned mining in the fully mechanized working face. The current mine electromagnetic pilot valve test methods use emulsion pump as a liquid source. The power consumption is large. In addition, the system pressure regulation uses manual adjustment, which is inefficient. In order to solve the above problems, a low-power test platform for reversing characteristics of mine electromagnetic pilot valve is designed. The platform consists of two parts: hydraulic system and measurement and control system. The hydraulic system mainly includes electric proportional valve, gas-liquid booster pump, valve to be tested, and accumulator. The double-headed gas-liquid booster pump is used as the liquid source so as to reduce energy consumption. The electric proportional valve is used to adjust the inlet air pressure of the gas-liquid booster pump. The inlet pressure of the tested valve is adjusted to the required value to realize the automatic regulation of the system pressure. The measurement and control system consists of upper computer, acquisition card, program control power supply, electric proportional valve controller (PID controller), and various sensors. According to the requirements of sensor installation and precision, the laser displacement sensor is selected to test the displacement of the electromagnet ejector rod. The PID controller is used to adjust the pressure of the liquid inlet of the electromagnetic pilot valve. The platform can realize the real-time dynamic monitoring and data storage of various performance indexes of the electromagnetic pilot valve in the reversing process. The indexes include voltage, current, inlet and outlet pressure, ejector rod displacement, dynamic response time and real-time power consumption, etc. The maximum power is only 800 W, which improves the test safety and efficiency, greatly reduces the system energy consumption, and provides an efficient and reliable test and verification means for researchers.
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图 2 换向过程中各参数变化时序
Figure 2. Time sequence of each parameter in the process of reversing
图 3 矿用电磁先导阀换向特性低功耗测试平台结构
1—气源；2—电气比例阀；3—双头气液增压泵；4—蓄能器；5—安全阀；6—被试阀；7—进口压力传感器；8—出口压力传感器；9—位移传感器；10—电流传感器；11—电压传感器；12—电控开关阀。
Figure 3. Structure of reversing characteristic test platform with low-power consumption for mine solenoid pilot valve
图 4 双头气液增压泵
1—双头气液增压泵；2—单向阀；3—增压缸；4—二位四通气控滑阀；5—消声器；6—二位二通导阀；7—电气比例阀；8—气源。
Figure 4. Double-headed gas liquid boost pump
图 8 矿用电磁先导阀换向特性低功耗测试平台
Figure 8. Low-power consumption test platform for reversing characteristic of mine solenoid pilot valve
图 9 电磁先导阀换向特性测试曲线
Figure 9. Reversing characteristic test curves of solenoid pilot valve
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