| The annual demand numbers of ceramic tile is nearly hundred million square meters in china,besides,our country is the largest producer of ceramic tile in the world.Unfortunately the heavy demand brings a huge amount of consumption of resources and energy.Obviously,the produce of ceramic tile in large size and thin shape can significantly reduce consumption.However,a more stringent requirement for the full automatic ceramic press of the molding core equipment is put forward.Under the new era of intelligent manufacturing,with a large number of measured data as the center,the research of precision control and improvement performance of the online state of the press has become a new developmental orientation in recent years.It is the key breakthrough technology for improving performance of ceramic press that the online data is acquired efficiently and the main faults are analyzed accurately.Therefore,this article researches the methods of online data acquisition for high efficiency and typical fault diagnosis base on the special characteristics of ceramic molding.On this basis,it research online testing system in modular design.The specific studies are as bellows:Firstly,the characteristics of electro-hydraulic system for ceramic press are analyzed,moreover,leakage characteristics and regularity of distortion control is determined.The electrical and hydraulic system of ceramic press is comprehensive analyzed base on the working principle and operation flow of press.In addition,the leakage characteristic and rule of the control distortion are studied,the mathematical model of the main cylinder pressing process is established according to the leakage characteristic.The failure characteristics of the leaking cylinder are studied based on the leakage characteristic model,which provides the basis for the follow-up research of testing system.Then,the stable and efficient state monitoring subsystem with online data is studied based on the modular design method.The overall architecture of test system is designed for the demand of the intelligent diagnosis of ceramic press.The equipment of data processing is designed,which can be used to preprocess the key signal of press in the aspect of hardware system.The high-speed and modular monitoring procedures are designed in the aspect of software system.Combined with the optimization framework of software design,the operation efficiency of software system is improved.In addition,the fault analysis subsystem with high precision is researched based on the theory of wavelet denoising and wavelet transform.The framework of failure analysis subsystem is established based on the modular design method.The characteristics of wavelet transform in local spectrum analysis is studied,the optimization model of wavelet denoising is established,which significantly better than the traditional filter denoising.Moreover,the characteristic of wavelet transform in mutation signal and different frequency section signal is analyzed and the accuracy of the wavelet transform on the singular signal monitoring is studied.Finally,the reliability of test system is verified combined with simulation analysis and field experiment.The correctness and reliability of test system is verified based on condition monitoring system established on the measuring press machine.The integrated simulation platform of press machine is established for the restriction that the fault signal of the press can not be extracted in the field.Meanwhile,the reliability of wavelet transforms that monitor the fault signal is verified with the method of numerical calculation and co-simulation.The innovative point of this paper is the design of test system on press by high efficient,and the designed system considers the online data monitoring and accurate fault diagnosis to provide protection for the breakthrough of the bottleneck of the press performance and the development of intelligence.With the actual working condition of press and load characteristic of ceramic powder,the integrated simulation platform of press machine is established.Through the wavelet analysis of the fault simulation signals,the leaks fault feature of master cylinder has be extracted in the non-destructive testing,which offer a new mean to for accurate diagnosis of fault of ceramic press. |
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