CN104697799A - Automatic load increase testing system and testing method for engine - Google Patents
Automatic load increase testing system and testing method for engine Download PDFInfo
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- CN104697799A CN104697799A CN201510105478.5A CN201510105478A CN104697799A CN 104697799 A CN104697799 A CN 104697799A CN 201510105478 A CN201510105478 A CN 201510105478A CN 104697799 A CN104697799 A CN 104697799A
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Abstract
The invention discloses an automatic load increase testing system and testing method for an engine. The automatic load increase testing system comprises the engine, a torque sensor, a gear transmission, a slave motor, an industrial control computer and a 4-quadrant frequency converter; the engine is connected with the torque sensor through a coupling, the other end of the torque sensor is connected with the gear transmission, the gear transmission is connected with the slave motor through a coupling, the slave motor is connected with the 4-quadrant frequency converter through a cable, and the industrial control computer is connected with the torque sensor and 4-quadrant frequency converter. The automatic load testing method for the engine includes that judging the similarity and difference between a theoretical load characteristic curve of the engine and an actual measured load characteristic testing curve to obtain an engine testing conclusion. The system and method are capable of realizing the automatic load increase testing, the testing precision of the system is improved, and the running time of the system is shortened.
Description
Technical field
The present invention relates to Engine Block Test field, relate to a kind of engine automatic Load in particular and load test macro.
Background technology
Engine is widely used on the equipments such as automobile, steamer, aircraft as core drive equipment.Engine of good performance, has higher security and outstanding performance.Important detection before Engine Block Test dispatches from the factory as engine, has important retroactive effect to the design of engine, and the height of test macro precision directly affects the performances evaluation of engine.
At present, most domestic Engine Block Test platform mainly adopts dynamometer machine to realize the given of load.By given load, manually record the correlation parameter after stablizing, draw out the load characteristic curve of engine.Adopt in this way, the test point of acquisition is few, and the test duration is long, and the often group data of test are not synchronization gained, have had a strong impact on the efficiency calculation of engine, causes measuring error to become large.
From the above, traditional load loading system, has the problems such as efficiency is low, low precision.
Summary of the invention
The object of the invention is to overcome the deficiencies in the prior art, provide a kind of engine automatic Load and load test macro and method of testing, improve the measuring accuracy of system, reduce the working time of system.
The present invention for achieving the above object, adopts following technical scheme:
A kind of engine automatic Load loads test macro, it is characterized in that: comprise engine, torque sensor, speed-changing gear box, accompany examination motor, industrial control computer and four-quadrant frequency converter; Described engine is connected with described torque sensor by shaft coupling, the other end of described torque sensor is connected to described speed-changing gear box, described speed-changing gear box accompanies examination motor described in being connected to through shaft coupling, described examination motor of accompanying is connected to described four-quadrant frequency converter by cable, and described industrial control computer is connected with four-quadrant frequency converter with torque sensor;
Described industrial control computer is used for the theoretical load characteristic curve of matching engine; According to the theoretical load characteristic curve formula of matching gained, calculate the power under rotating speed to be measured and torque value, be stored into the reserved location of four-quadrant frequency converter by the form of two-dimensional array; The theoretical load characteristic curve of contrast engine and actual measurement part throttle characteristics test curve, judge similarity and the deviation of two curves, draw Engine Block Test conclusion, the load characteristic curve data of test gained are stored into as requested the assigned address of industrial control computer;
Described four-quadrant frequency converter adopts Direct Torque Control mode to control accompanying examination motor, by the given control of four-quadrant frequency converter torque, realizes the automatically given of engine loading; Calculate the engine loading power in test process, by rotating speed, torque and bearing power data upload to industrial control computer.
It is further characterized in that: after the AC rectification of accompanying examination motor to send is become direct current by described four-quadrant frequency converter, converting voltage to by inversion module is 220V, and frequency is the alternating current of 50Hz and feeds back to electrical network; Detect engine rotational speed signal, the two-dimensional array of inquiry storage inside, obtains the torque value under corresponding rotating speed, detects the three-phase voltage U that inverter exports in real time
a, U
b, U
cand electric current I
a, I
b, I
c, calculate the stator magnetic linkage ψ accompanying examination motor, try to achieve the electromagnetic torque T of motor according to the stator magnetic linkage ψ calculated
e, realize the automatically given of engine loading.
Described accompany examination motor be standard three-phase squirrel cage type asynchronous machine.
Adopt above-mentioned engine automatic Load to load an engine automatic Load method of testing for test macro, it is characterized in that, comprise the steps:
(1) industrial control computer adopts the theoretical load characteristic curve of least square fitting engine; According to the theoretical load characteristic curve formula of matching gained, calculate the power under rotating speed to be measured and torque value, be stored into the reserved location of four-quadrant frequency converter by the pattern of two-dimensional array;
(2) four-quadrant frequency converter reads rotating speed and the dtc signal of torque sensor, according to formula P=T
n/ 9550 calculate the bearing power in test process, by tcp/ip communication agreement by rotating speed, torque and bearing power data upload to industrial control computer, the data received are saved in the EXCEL file of specifying by industrial control computer with metric form;
(3) industrial control computer with engine output speed and torque for sentencing steady condition, the steady state (SS) of automatic decision test data; The rotating speed of automatic read test, torque and bearing power parameter, calculate the rotating speed n of engine under each steady state (SS)
iwith mean square deviation S
ni, torque T
iwith mean square deviation S
ti; Calculate the rotating speed mean value of whole piece curve steady testing point
average of torque
and the correlation coefficient r of rotating speed and torque, if correlation coefficient r is greater than setting value r
set, then think that test rationally, otherwise reload test; Wherein, the computing formula of rotating speed and torque related coefficient is as follows:
(4) industrial control computer matching is tested the load characteristic curve of gained and is contrasted with the theoretical load characteristic curve of engine, if two Similar Broken Line and deviation are in range of set value, then think that engine reaches designing requirement, otherwise think that engine design is defective.
The form that in described step (1), the data of two-dimensional array store is:
A
ii＝[a
11，a
12，a
13；a
21，a
22，a
23；......；a
i1，a
i2，a
i3]
Wherein, α
i1column data represents rotating speed, α
i2column data represents torque, α
i3column data represents power.
In described step (3), the step of the steady state (SS) of automatic decision test data is:
To the calculated value S of specific speed mean square deviation
niwith set-point S
nisetif, calculated value S
nibe greater than set-point S
niset, then stabilization of speed nargin ε is reduced
n, recalculate and judge, if calculated value S
nibe less than set-point S
niset, then think that stabilization of speed scope is chosen rationally; To the calculated value S of specific torque mean square deviation
tiwith set-point S
tisetif, calculated value S
tibe greater than set-point S
tiset, then torque stability margin ε is reduced
t, recalculate and judge, if calculated value S
tibe less than set-point S
tiset, then think that torque range of stability is chosen rationally; The row at array place when mark rotating speed and torque are stablized, array when extraction rotating speed and torque are all stablized, according to given rotating speed n
iset, obtain the test rotating speed n of its correspondence
i, torque T
iwith bearing power P
i.
Present system and method can realize engine automatic Load and load test, improve the measuring accuracy of system, reduce the working time of system.Accompanied by driven by engine examination motor electricity to feed back to electrical network simultaneously, thus reach energy-conservation object.
Accompanying drawing explanation
Fig. 1 is that a kind of engine automatic Load loads test principle figure.
Fig. 2 is host computer flow chart of data processing figure.
Embodiment
Below in conjunction with the drawings and specific embodiments, the invention will be further described:
In Fig. 1, a kind of engine automatic Load loads test macro, comprises engine, torque sensor, speed-changing gear box, accompanies examination motor, industrial control computer and four-quadrant frequency converter; Engine is connected with torque sensor by shaft coupling, and the other end of torque sensor is connected to speed-changing gear box, and speed-changing gear box is connected to through shaft coupling and accompanies examination motor, accompanies examination motor to be connected to four-quadrant frequency converter by cable.Torque sensor adopts JN-338 type torque sensor, and the rotating speed that torque sensor exports and dtc signal are connected to the signal acquisition module of four-quadrant frequency converter by signal shielding cable.
Industrial control computer adopts the theoretical load characteristic curve of least square fitting engine; According to the theoretical load characteristic curve formula of matching gained, calculate the power under rotating speed to be measured and torque value, be stored into the reserved location of four-quadrant frequency converter by the form of two-dimensional array.
The form that data store is:
A
ii＝[a
11，a
12，a
13；a
21，a
22，a
23；......；a
i1，a
i2，a
i3]
Wherein, α
i1column data represents rotating speed, α
i2column data represents torque, α
i3column data represents power.
Accompany the standard three-phase squirrel cage type asynchronous machine that examination motor adopts ABB electrical machinery plant to produce.
After the AC rectification of accompanying examination motor to send is become direct current by four-quadrant frequency converter, converting voltage to by inversion module is 220V, and frequency is the alternating current of 50Hz and feeds back to electrical network;
Automatic Load loading system adopts the C language programming under MATLAB environment, realizes the process to image data, data processor with output speed and torque for sentencing steady condition, the steady state (SS) of automatic decision test data; The rotating speed of automatic read test, the parameter such as torque and bearing power, calculate the rotating speed n of engine under each steady state (SS)
iwith mean square deviation S
ni, torque T
iwith mean square deviation S
ti; Calculate the rotating speed mean value of whole piece curve steady testing point
average of torque
and the correlation coefficient r of rotating speed and torque.Wherein, the computing formula of rotating speed and torque related coefficient is as follows:
The program flow diagram of data processing as shown in Figure 2, before service data handling procedure, carries out initialization to each group of parameter, then reads the data of specifying in EXCEL file, surveys average and the variance of rotating speed and torque under each given rotating speed of calculation engine.To the calculated value S of specific speed mean square deviation
niwith set-point S
nisetif, calculated value S
nibe greater than set-point S
niset, then stabilization of speed nargin ε is reduced
n, recalculate and judge, if calculated value S
nibe less than set-point S
niset, then think that stabilization of speed scope is chosen rationally; To the calculated value S of specific torque mean square deviation
tiwith set-point S
tisetif, calculated value S
tibe greater than set-point S
tiset, then torque stability margin ε is reduced
t, recalculate and judge, if calculated value S
tibe less than set-point S
tiset, then think that torque range of stability is chosen rationally; The row at array place when mark rotating speed and torque are stablized, array when extraction rotating speed and torque are all stablized, according to given rotating speed n
iset, obtain the test rotating speed n of its correspondence
i, torque T
iwith bearing power P
i.Calculate the mean value of rotating speed under whole piece part throttle characteristics test curve stable condition, torque and bearing power, i.e. conduct respectively
calculate the correlation coefficient r of whole piece test curve torque and rotational speed, if correlation coefficient r is greater than setting value r
set, then think that test rationally, otherwise need test be reloaded; The load characteristic curve of matching test gained also contrasts with the Design cooling load family curve of engine, if the higher and deviation of two curve similarities is in rational scope, then thinks that engine reaches designing requirement, otherwise thinks that engine design is defective.The load characteristic curve of test gained is stored into as requested the assigned address of industrial control computer.
Four-quadrant frequency converter is according to the tach signal recorded, and the two-dimensional array of inquiry storage inside, obtains the torque value under corresponding rotating speed, this torque numerical value is sent to the given register of torque of setting; The controller of four-quadrant frequency converter reads the value of the given register of torque, detects the three-phase voltage U that inverter exports in real time
a, U
b, U
cand electric current I
a, I
b, I
c, calculate the stator magnetic linkage ψ accompanying examination motor, try to achieve the electromagnetic torque T of motor according to the stator magnetic linkage ψ calculated
e, adopt Direct Torque Control mode to control to accompany examination motor; By to the given control of four-quadrant frequency converter torque, realize the automatically given of engine loading.
Four-quadrant frequency converter reads rotating speed and the dtc signal of torque sensor, according to formula P=T
n/ 9550 calculate the bearing power in test process, by tcp/ip communication agreement by data upload such as rotating speed, torque and bearing powers to industrial control computer, the data received are saved in metric form in the EXCEL file of specifying by industrial control computer.
After test terminates, the industrial control computer Automatically invoked network printer, according to the printed report form of setting, the test report of print engine, by test report stored in database.
Claims (6)
1. engine automatic Load loads a test macro, it is characterized in that: comprise engine, torque sensor, speed-changing gear box, accompany examination motor, industrial control computer and four-quadrant frequency converter; Described engine is connected with described torque sensor by shaft coupling, the other end of described torque sensor is connected to described speed-changing gear box, described speed-changing gear box accompanies examination motor described in being connected to through shaft coupling, described examination motor of accompanying is connected to described four-quadrant frequency converter by cable, and described industrial control computer is connected with four-quadrant frequency converter with torque sensor;
Described industrial control computer is used for the theoretical load characteristic curve of matching engine; According to the theoretical load characteristic curve formula of matching gained, calculate the power under rotating speed to be measured and torque value, be stored into the reserved location of four-quadrant frequency converter by the form of two-dimensional array; The theoretical load characteristic curve of contrast engine and actual measurement part throttle characteristics test curve, judge similarity and the deviation of two curves, draw Engine Block Test conclusion, the load characteristic curve data of test gained are stored into as requested the assigned address of industrial control computer;
Described four-quadrant frequency converter adopts Direct Torque Control mode to control accompanying examination motor, by the given control of four-quadrant frequency converter torque, realizes the automatically given of engine loading; Calculate the engine loading power in test process, by rotating speed, torque and bearing power data upload to industrial control computer.
2. engine automatic Load according to claim 1 loads test macro, it is characterized in that: after the AC rectification of accompanying examination motor to send is become direct current by described four-quadrant frequency converter, converting voltage to by inversion module is 220V, and frequency is the alternating current of 50Hz and feeds back to electrical network; Detect engine rotational speed signal, the two-dimensional array of inquiry storage inside, obtains the torque value under corresponding rotating speed, detects the three-phase voltage U that inverter exports in real time
a, U
b, U
cand electric current I
a, I
b, I
c, calculate the stator magnetic linkage ψ accompanying examination motor, try to achieve the electromagnetic torque T of motor according to the stator magnetic linkage ψ calculated
e, realize the automatically given of engine loading.
3. engine automatic Load according to claim 1 loads test macro, it is characterized in that: described in accompany examination motor to be standard three-phase squirrel cage type asynchronous machine.
4. adopt engine automatic Load described in any one of claim 1-3 to load an engine automatic Load method of testing for test macro, it is characterized in that, comprise the steps:
(1) industrial control computer adopts the theoretical load characteristic curve of least square fitting engine; According to the theoretical load characteristic curve formula of matching gained, calculate the power under rotating speed to be measured and torque value, be stored into the reserved location of four-quadrant frequency converter by the pattern of two-dimensional array;
(2) four-quadrant frequency converter reads rotating speed and the dtc signal of torque sensor, according to formula P=T
n/ 9550 calculate the bearing power in test process, by tcp/ip communication agreement by rotating speed, torque and bearing power data upload to industrial control computer, the data received are saved in the EXCEL file of specifying by industrial control computer with metric form;
(3) industrial control computer with engine output speed and torque for sentencing steady condition, the steady state (SS) of automatic decision test data; The rotating speed of automatic read test, torque and bearing power parameter, calculate the rotating speed n of engine under each steady state (SS)
iwith mean square deviation S
ni, torque T
iwith mean square deviation S
ti; Calculate the rotating speed mean value of whole piece curve steady testing point
average of torque
and the correlation coefficient r of rotating speed and torque, if correlation coefficient r is greater than setting value r
set, then think that test rationally, otherwise reload test; Wherein, the computing formula of rotating speed and torque related coefficient is as follows:
(4) industrial control computer matching is tested the load characteristic curve of gained and is contrasted with the theoretical load characteristic curve of engine, if two Similar Broken Line and deviation are in range of set value, then think that engine reaches designing requirement, otherwise think that engine design is defective.
5. engine automatic Load method of testing according to claim 4, is characterized in that: the form that in described step (1), the data of two-dimensional array store is:
A
ij＝[a
11，a
12，a
13；a
21，a
22，a
23；......；a
i1，a
i2，a
i3]
Wherein, α
i1column data represents rotating speed, α
i2column data represents torque, α
i3column data represents power.
6. engine automatic Load method of testing according to claim 5, is characterized in that: in described step (3), the step of the steady state (SS) of automatic decision test data is:
To the calculated value S of specific speed mean square deviation
niwith set-point S
nisetif, calculated value S
nibe greater than set-point S
niset, then stabilization of speed nargin ε is reduced
n, recalculate and judge, if calculated value S
nibe less than set-point S
niset, then think that stabilization of speed scope is chosen rationally; To the calculated value S of specific torque mean square deviation
tiwith set-point S
tisetif, calculated value S
tibe greater than set-point S
tiset, then torque stability margin ε is reduced
t, recalculate and judge, if calculated value S
tibe less than set-point S
tiset, then think that torque range of stability is chosen rationally; The row at array place when mark rotating speed and torque are stablized, array when extraction rotating speed and torque are all stablized, according to given rotating speed n
iset, obtain the test rotating speed n of its correspondence
i, torque T
iwith bearing power P
i.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201510105478.5A CN104697799B (en) | 2015-03-10 | 2015-03-10 | A kind of engine automatic Load loads test system and method for testing |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201510105478.5A CN104697799B (en) | 2015-03-10 | 2015-03-10 | A kind of engine automatic Load loads test system and method for testing |
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| Publication Number | Publication Date |
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| CN104697799A true CN104697799A (en) | 2015-06-10 |
| CN104697799B CN104697799B (en) | 2017-05-31 |
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Cited By (6)
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| CN107085185A (en) * | 2017-05-15 | 2017-08-22 | 中车株洲电机有限公司 | A kind of motor temperature-raising experiment device |
| CN108804301A (en) * | 2017-04-27 | 2018-11-13 | 株洲中车时代电气股份有限公司 | A kind of train control system software testing system and method based on E & FR data |
| CN109697296A (en) * | 2017-10-20 | 2019-04-30 | 株洲中车时代电气股份有限公司 | Transmission system fast design method and device based on frequency-conversion alternating current motor |
| CN109709469A (en) * | 2018-12-25 | 2019-05-03 | 无锡市大元广盛电气股份有限公司 | A kind of four-in-one variable-frequency governor load test approach and its load testing fixture |
| CN113211426A (en) * | 2020-12-02 | 2021-08-06 | 格创东智(深圳)科技有限公司 | Robot fault diagnosis method and device, computer equipment and storage medium |
| CN113588271A (en) * | 2021-07-23 | 2021-11-02 | 东风汽车集团股份有限公司 | Catalyst emission test substitutability verification system and method based on power assembly rack |
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| CN108804301A (en) * | 2017-04-27 | 2018-11-13 | 株洲中车时代电气股份有限公司 | A kind of train control system software testing system and method based on E & FR data |
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| CN109709469A (en) * | 2018-12-25 | 2019-05-03 | 无锡市大元广盛电气股份有限公司 | A kind of four-in-one variable-frequency governor load test approach and its load testing fixture |
| CN113211426A (en) * | 2020-12-02 | 2021-08-06 | 格创东智(深圳)科技有限公司 | Robot fault diagnosis method and device, computer equipment and storage medium |
| CN113211426B (en) * | 2020-12-02 | 2023-02-28 | 格创东智(深圳)科技有限公司 | Robot fault diagnosis method and device, computer equipment and storage medium |
| CN113588271A (en) * | 2021-07-23 | 2021-11-02 | 东风汽车集团股份有限公司 | Catalyst emission test substitutability verification system and method based on power assembly rack |
| CN113588271B (en) * | 2021-07-23 | 2024-04-09 | 东风汽车集团股份有限公司 | Catalyst emission test substitutability verification system and method based on power assembly rack |
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|---|---|
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