CN112346360B - Wind tunnel test flow verification method for mixed execution of actual operation and simulation - Google Patents
Wind tunnel test flow verification method for mixed execution of actual operation and simulation Download PDFInfo
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Abstract
The invention discloses a wind tunnel test flow verification method implemented by mixing actual operation and simulation. The wind tunnel test flow verification method is based on a wind tunnel control program, a corresponding control module is arranged for each field device in the wind tunnel control program, and each control module is provided with a mode switching interface, a set of actual input and output interfaces, a set of program control intermediate interfaces and a simulation submodule. The wind tunnel test flow verification method can flexibly configure field equipment needing simulation or actual operation, in the flow verification process, the equipment set as simulation only executes simulation action, and the equipment set as actual operation executes actual action, so that the actual working state of the field equipment concerned mainly can be checked whether to meet the requirements or not while the time sequence and logic interlocking relation of the wind tunnel test flow is verified. The wind tunnel test flow verification method does not need additional software and hardware resources and can be realized in any universal controller and matched development software.
Description
Technical Field
The method belongs to the technical field of wind tunnel tests, and particularly relates to a wind tunnel test flow verification method implemented by mixing actual operation and simulation.
Background
The safety problem of the hypersonic high-temperature wind tunnel is outstanding, the wind tunnel test relates to various dangerous media such as inflammable, explosive, strong oxidation, deep cooling and the like, equipment is in high-pressure, strong vibration, high-temperature and cold-heat exchange environment, and the dangerous factors are numerous. The time and economic cost of wind tunnel testing is high: before a wind tunnel test, the time consumption of the inspection and preparation processes of hundreds of devices of nearly 10 systems of a hypersonic high-temperature wind tunnel is averagely 4-8 hours; the caliber of the hypersonic high-temperature wind tunnel reaches 3 meters, the flow rate is hundreds of kilograms per second, and the consumption cost of one-time dynamic combustion reaches more than ten-thousand yuan. The wind tunnel test flow is complex, and related field devices of a plurality of systems such as fuel, liquid oxygen, liquid nitrogen, high-pressure air, nitrogen, vacuum, cooling water, model feeding, measurement and the like are required to be accurately cooperated by a wind tunnel control program, so that the wind tunnel control program can act and respond according to time sequence and interlocking conditions strictly, and the safety of each system of the hypersonic-speed high-temperature wind tunnel and the effective test result are ensured.
During the wind tunnel test process, corresponding adjustment and optimization are always carried out according to different test state parameters and actual working conditions of equipment. Because the wind tunnel system equipment has a strong coupling relation of time sequence and interlocking, any change in the wind tunnel test flow can affect a plurality of related steps, and the wind tunnel control program has to carry out corresponding design change one by one, so that the workload is huge.
Adjustment of wind tunnel test procedures and changes to wind tunnel control programs introduce multiple risk factors: firstly, because the test responsible person considers the changes, changes of some relevant links are omitted in the wind tunnel test flow; secondly, a software engineer cannot accurately understand the wind tunnel test flow, and the time sequence and logic cannot completely meet the test requirements; and thirdly, the control program code has bug errors and cannot be smoothly executed according to the expected design requirements. These risks are particularly acute during the device and test commissioning phases. For a hypersonic high-temperature wind tunnel, if the risk factors exist, once the actual operation is started, the payment cost is very high: if the data is not valid, manpower and material resources are wasted; accidents such as damage, explosion, combustion and the like of wind tunnel equipment occur.
Meanwhile, as the field equipment of the hypersonic high-temperature wind tunnel is frequently operated under a high-load condition, abrasion or aging inevitably occurs, so that the dynamic characteristics of the field equipment can be changed to different degrees, the time sequence requirement of the previous test flow cannot be met, even faults occur, and the safety of the wind tunnel equipment and personnel is seriously influenced.
In order to eliminate the risk factors to the maximum extent, the wind tunnel operating regulations require that necessary correctness and feasibility tests be carried out after each flow adjustment and control program change; moreover, after the performance of a certain device is detected to be changed obviously or maintenance is carried out due to a fault, the device is required to perform actual action in the verification process of the wind tunnel test flow, and the device is confirmed to be in a good state and can participate in the test.
Currently, there is a need to develop a wind tunnel test flow verification method with mixed execution of real operation and simulation.
Disclosure of Invention
The invention aims to provide a wind tunnel test flow verification method for mixed execution of actual operation and simulation.
The invention discloses a wind tunnel test flow verification method implemented by mixing actual operation and simulation, which is characterized in that the wind tunnel test flow verification method is based on a wind tunnel control program, a corresponding control module is arranged for each field device in the wind tunnel control program, and each control module is provided with a mode switching interface, a set of actual input and output interfaces, a set of program control intermediate interfaces and a simulation submodule;
the mode switching interface is used for selecting the control module to execute real operation or simulation, and interface signals of the mode switching interface are set by an operator through the host computer; if the 'real operation' is selected, the control module is connected with the program control intermediate interface and the actual input/output interface, controls the action of the field equipment and obtains the actual feedback data of the field equipment; if simulation is selected, the control module disconnects the program control intermediate interface from the actual input/output interface, and the simulation submodule simulates the action of the field device and provides a simulation feedback value of the field device; the mode switching interfaces of the control modules are independently arranged and do not influence each other;
the actual input/output interface is connected to the field device, the actual input interface in the actual input/output interface receives the opening and closing related state signals fed back by the field device, and the actual output interface in the actual input/output interface transmits action command signals to the field device to drive the field device to execute opening and closing actions;
the program control intermediate interface provides all intermediate data to be interacted between the control modules of the field devices and between the field devices and the upper computer; the wind tunnel control program carries out read-write operation on the signal of the program control intermediate interface, indirectly controls the action of the field equipment and acquires the state of the field equipment;
the simulation submodule is circularly scanned and executed during simulation, and dynamic characteristic parameters of opening and closing of corresponding field equipment, which are provided by a manufacturer or obtained during debugging of the field equipment, are stored;
the method comprises the following steps:
a. an operator selects field equipment needing to execute simulation through an upper computer;
b. setting dynamic characteristic parameters for a control module of the field device by an operator;
c. setting a wind tunnel control program to execute mixed simulation by an operator;
for the field device selected in the step a, a control module of the field device receives a simulation instruction, and firstly, an output signal of an actual input/output interface is latched; then disconnecting the program control intermediate interface from the actual input/output interface; then connecting the program control intermediate interface with the interface of the simulation submodule; finally, according to a pre-designed test flow, the wind tunnel control program transmits an opening or closing command to the simulation submodule through the program control intermediate interface, the simulation submodule carries out calculation according to the dynamic characteristic parameters of the field equipment, changes the parameters related to the opening and closing in-place indication and the opening indication value of the program control intermediate interface in real time, simulates the action of the field equipment and transmits a feedback signal to the wind tunnel control program through the program control intermediate interface;
for the field devices which are not selected in the step a, the wind tunnel control program transmits opening or closing commands to the actual output interfaces of the control modules corresponding to the field devices through the program control intermediate interfaces, the field devices are driven to execute corresponding opening or closing actions, and meanwhile, the actual input interfaces transmit read state parameters of the field devices to the program control intermediate interfaces and further feed back the state parameters to the wind tunnel control program;
d. c, the wind tunnel control program drives the control modules of the field devices one by one according to the time sequence and logic interlocking conditions of the test flow and the working process of the step c to obtain feedback signals until the 'hybrid simulation' of the test flow is finished;
e. the test responsible person and the software engineer readjust the test flow and the wind tunnel control program according to the simulation result of the hybrid simulation until the time sequence and logic interlocking conditions in the test flow meet the test requirements;
f. setting the mode of a wind tunnel control program to be 'real operation' by an operator through an upper computer; for the field device selected in the step a, the wind tunnel control program controls the corresponding variable of the intermediate interface according to the output signal of the actual input/output interface latched in the step c by the back-writing program; then restoring the connection between the program control intermediate interface and the actual input/output interface; at this time, the program control intermediate interface signal, the actual input/output interface signal and the state of the field device of the control module of the selected field device in the step a are consistent and are the states before simulation;
g. after the hybrid simulation is finished, the wind tunnel control program enters an actual operation state, the connection between program control intermediate interfaces of all field device control modules and actual input and output interfaces is switched on, and when the program control intermediate interfaces receive command signals for opening and closing, the field devices are immediately driven to execute corresponding actions; and reading the actual in-place opening and closing and opening related state parameters of the field equipment in real time, and feeding back the state parameters to the wind tunnel control program.
The wind tunnel test flow verification method of the mixed execution of the real operation and the simulation can flexibly configure field equipment needing to execute the simulation and the real operation according to the requirement, the field equipment is set as the simulation equipment in the flow verification process, a control program simulates the action of the field equipment, and the field equipment always maintains the state before the simulation in the switching process of the real operation, the simulation and the real operation, the misoperation can not occur, and the safety of a wind tunnel system in the simulation process is ensured; the field device set to "real operation" then actually performs the action and feeds back the actual state of the field device. Therefore, the method can verify the time sequence and logic interlocking relationship of the wind tunnel test process safely, effectively and quickly, and simultaneously verify whether the actual working state of the field device which is focused on meets the requirements or not.
The real operation and the simulation in the wind tunnel test flow verification method of the mixed execution of the real operation and the simulation are realized by the same wind tunnel control program, the test flow control is completely the same, the simulation effect is real and direct, the real operation and the simulation are immediately and simultaneously effective after the adjustment and the modification of the time sequence and the logic interlocking relationship, the secondary modification and the transplantation are not needed, and the extra workload is very small. "simulation" can faithfully simulate the dynamic course of field device actions to confirm timing and interlocking relationships, or can artificially speed up or slow down the actions of the field device to speed up the simulation process or simulate field device faults.
The wind tunnel test flow verification method based on the mixed execution of the actual operation and the simulation does not need additional software and hardware resources, and can be realized in any universal controller and matched development software.
Drawings
Fig. 1 is a schematic diagram of a working principle of a wind tunnel control program in a wind tunnel test flow verification method by mixing actual operation and simulation.
Detailed Description
The present invention will be described in detail below with reference to the accompanying drawings and examples.
As shown in fig. 1, the wind tunnel test flow verification method of mixed execution of actual operation and simulation of the present invention is based on a wind tunnel control program, in which a corresponding control module is provided for each field device, and each control module is provided with a mode switching interface, a set of actual input and output interfaces, a set of program control intermediate interfaces, and a simulation submodule;
the mode switching interface is used for selecting the control module to execute real operation or simulation, and interface signals of the mode switching interface are set by an operator through the host computer; if the 'real operation' is selected, the control module is connected with the program control intermediate interface and the actual input/output interface, controls the action of the field equipment and obtains the actual feedback data of the field equipment; if simulation is selected, the control module disconnects the program control intermediate interface from the actual input/output interface, and the simulation submodule simulates the action of the field device and provides a simulation feedback value of the field device; the mode switching interfaces of the control modules are independently arranged and do not influence each other;
the actual input/output interface is connected to the field device, the actual input interface in the actual input/output interface receives the opening and closing related state signals fed back by the field device, and the actual output interface in the actual input/output interface transmits action command signals to the field device to drive the field device to execute opening and closing actions;
the program control intermediate interface provides all intermediate data to be interacted between the control modules of the field devices and between the field devices and the upper computer; the wind tunnel control program carries out read-write operation on the signal of the program control intermediate interface, indirectly controls the action of the field equipment and acquires the state of the field equipment;
the simulation submodule is circularly scanned and executed during simulation, and dynamic characteristic parameters of opening and closing of corresponding field equipment, which are provided by a manufacturer or obtained during debugging of the field equipment, are stored;
the method comprises the following steps:
a. an operator selects field equipment needing to execute simulation through an upper computer;
b. setting dynamic characteristic parameters for a control module of the field device by an operator;
c. setting a wind tunnel control program to execute mixed simulation by an operator;
for the field device selected in the step a, a control module of the field device receives a simulation instruction, and firstly, an output signal of an actual input/output interface is latched; then disconnecting the program control intermediate interface from the actual input/output interface; then connecting the program control intermediate interface with the interface of the simulation submodule; finally, according to a pre-designed test flow, the wind tunnel control program transmits an opening or closing command to the simulation submodule through the program control intermediate interface, the simulation submodule carries out calculation according to the dynamic characteristic parameters of the field equipment, changes the parameters related to the opening and closing in-place indication and the opening indication value of the program control intermediate interface in real time, simulates the action of the field equipment and transmits a feedback signal to the wind tunnel control program through the program control intermediate interface;
for the field devices which are not selected in the step a, the wind tunnel control program transmits opening or closing commands to the actual output interfaces of the control modules corresponding to the field devices through the program control intermediate interfaces, the field devices are driven to execute corresponding opening or closing actions, and meanwhile, the actual input interfaces transmit read state parameters of the field devices to the program control intermediate interfaces and further feed back the state parameters to the wind tunnel control program;
d. c, the wind tunnel control program drives the control modules of the field devices one by one according to the time sequence and logic interlocking conditions of the test flow and the working process of the step c to obtain feedback signals until the 'hybrid simulation' of the test flow is finished;
e. the test responsible person and the software engineer readjust the test flow and the wind tunnel control program according to the simulation result of the hybrid simulation until the time sequence and logic interlocking conditions in the test flow meet the test requirements;
f. setting the mode of a wind tunnel control program to be 'real operation' by an operator through an upper computer; for the field device selected in the step a, the wind tunnel control program controls the corresponding variable of the intermediate interface according to the output signal of the actual input/output interface latched in the step c by the back-writing program; then restoring the connection between the program control intermediate interface and the actual input/output interface; at this time, the program control intermediate interface signal, the actual input/output interface signal and the state of the field device of the control module of the selected field device in the step a are consistent and are the states before simulation;
g. after the hybrid simulation is finished, the wind tunnel control program enters an actual operation state, the connection between program control intermediate interfaces of all field device control modules and actual input and output interfaces is switched on, and when the program control intermediate interfaces receive command signals for opening and closing, the field devices are immediately driven to execute corresponding actions; and reading the actual in-place opening and closing and opening related state parameters of the field equipment in real time, and feeding back the state parameters to the wind tunnel control program.
Example 1
The embodiment is an application example of a hypersonic high-temperature wind tunnel. The specific situation is as follows: the newly modified test flow requires that the air throttle valve is opened when T is 0 seconds; opening the air main valve when T is 1 second; and when the T is 3 seconds, carrying out valve position interpretation, if the main valve is completely opened and the opening of the regulating valve is more than 60%, switching to a liquid oxygen filling process, and otherwise, switching to an emergency stop operation process. Meanwhile, since the main valve is maintained due to wear, it is necessary to actually check the operation state of the main valve. The main valve is set to be 'real operation', other equipment is set to be 'simulation', no medium flows in the wind tunnel when the test process is executed, the system is safe, and the actual condition of the main valve is also confirmed while the test process is verified. According to the data given by the valve manufacturer, the full-open time of the throttle valve is 4 seconds, the valve position is linearly increased along with the time, and the estimated open time is 1.9 seconds after the main valve is maintained. The wind tunnel control program is in the actual operation state, the main valve is in the closed state, and the throttle valve entity opening degree is 0%. The simulation process of the test flow comprises the following steps:
a. the operator sets the main valve as 'real operation' on the upper computer interface, and all the other devices are selected as 'simulation' mode;
b. the operator set the throttle full open time to 4 seconds;
c. setting a wind tunnel control program to execute mixed simulation by an operator;
except the main valve, the control modules of the throttle valve and other field devices receive a simulation instruction, and output signals of the actual input and output interfaces are latched firstly; then, the connection between the program control intermediate interface and the actual input/output interface is disconnected, and then the connection between the program control intermediate interface and the simulation submodule is connected, namely the connection is shown by a dotted line in fig. 1;
when T is equal to 0, the wind tunnel control program sets an opening command signal of an intermediate interface of the throttle valve control module to be 1, the throttle valve simulation submodule detects the opening command and determines to open the valve, and according to a set value, the opening indication signal of the throttle valve is linearly increased by 100% from 0% in the following 4 seconds;
when T is 1, the wind tunnel control program sets the opening command signal of the intermediate interface of the main valve control module to 1, and since the main valve does not receive the "emulation" command, the main valve program controls the intermediate interface to remain connected with the actual input/output interface, as shown by the solid line in fig. 1, the opening signal of the actual output interface is set to 1 at this time, the main valve is driven to perform the opening action, and the main valve is actually opened after 1.95 seconds;
when T is 3, the wind tunnel control program carries out valve position interpretation, the simulation opening degree of the throttle valve is 75%, the main valve is opened in place, the interlocking condition is met, and the process is switched to a liquid oxygen filling process;
d. the wind tunnel control program continues to execute subsequent processes, and an operator observes simulation conditions of other field devices and execution results of the test processes on an upper computer interface in real time until all the processes are simulated and executed for 10 seconds;
e. the method comprises the steps that an operator switches a wind tunnel control system back to an actual operation mode, except for a main valve, other field device control modules write back corresponding variables of a program control intermediate interface by using output signals of a device actual input and output interface latched before simulation, wherein a valve opening command signal of a throttle valve intermediate interface is set to be 0, a valve closing command signal is set to be 1, connection of the program control intermediate interface and the actual input and output interface is restored, the opening degree indication of the throttle valve intermediate interface is 0%, and interface signals are consistent with the states of field devices and are the states before simulation; the main valve still maintains the opened state in the process of flow verification, the main valve program controls the opening command and the opening position of the intermediate interface to be 1, the actual output interface opening signal and the opening position feedback are 1, and the actual output interface opening signal and the opening position feedback are consistent with the actual state of the main valve;
f. the wind tunnel control program is set to be in a real operation mode on an upper computer interface by an operator, enters a real operation state, and operates field equipment such as a main valve, a throttle valve and the like to complete corresponding actions.
In the embodiment, the hybrid simulation is selected on the upper computer interface, the simulation and the actual operation hybrid execution of the wind tunnel equipment are realized during the verification of the test flow, the test flow runs for 10 seconds, the detection on the correctness and the feasibility of the flow is finished, the actual action condition of the main valve after maintenance is basically in accordance with the expectation, and the test requirement can be met. The wind tunnel test flow verification method based on the mixed execution of the actual operation and the simulation proves to be safe, reliable, strong in practicability and good in flexibility, and can solve the practical engineering problem.
Although embodiments of the invention have been disclosed above, it is not intended to be limited to the uses set forth in the specification and examples, but rather, to one skilled in the art, all features of the invention disclosed, or all steps of any method or process so disclosed, may be combined in any suitable manner, except for mutually exclusive features and/or steps, without departing from the principles of the invention. It is therefore intended that the invention not be limited to the exact details and illustrations described and illustrated herein, but fall within the scope of the appended claims and equivalents thereof.
Claims (1)
1. A wind tunnel test flow verification method for mixed execution of actual operation and simulation is characterized in that the wind tunnel test flow verification method is based on a wind tunnel control program, a corresponding control module is arranged for each field device in the wind tunnel control program, and each control module is provided with a mode switching interface, a set of actual input and output interfaces, a set of program control intermediate interfaces and a simulation submodule;
the mode switching interface is used for selecting the control module to execute real operation or simulation, and interface signals of the mode switching interface are set by an operator through the host computer; if the 'real operation' is selected, the control module is connected with the program control intermediate interface and the actual input/output interface, controls the action of the field equipment and obtains the actual feedback data of the field equipment; if simulation is selected, the control module disconnects the program control intermediate interface from the actual input/output interface, and the simulation submodule simulates the action of the field device and provides a simulation feedback value of the field device; the mode switching interfaces of the control modules are independently arranged and do not influence each other;
the actual input/output interface is connected to the field device, the actual input interface in the actual input/output interface receives the opening and closing related state signals fed back by the field device, and the actual output interface in the actual input/output interface transmits action command signals to the field device to drive the field device to execute opening and closing actions;
the program control intermediate interface provides all intermediate data to be interacted between the control modules of the field devices and between the field devices and the upper computer; the wind tunnel control program carries out read-write operation on the signal of the program control intermediate interface, indirectly controls the action of the field equipment and acquires the state of the field equipment;
the simulation submodule is circularly scanned and executed during simulation, and dynamic characteristic parameters of opening and closing of corresponding field equipment, which are provided by a manufacturer or obtained during debugging of the field equipment, are stored;
the method comprises the following steps:
a. an operator selects field equipment needing to execute simulation through an upper computer;
b. setting dynamic characteristic parameters for a control module of the field device by an operator;
c. setting a wind tunnel control program to execute mixed simulation by an operator;
for the field device selected in the step a, a control module of the field device receives a simulation instruction, and firstly, an output signal of an actual input/output interface is latched; then disconnecting the program control intermediate interface from the actual input/output interface; then connecting the program control intermediate interface with the interface of the simulation submodule; finally, according to a pre-designed test flow, the wind tunnel control program transmits an opening or closing command to the simulation submodule through the program control intermediate interface, the simulation submodule carries out calculation according to the dynamic characteristic parameters of the field equipment, changes the parameters related to the opening and closing in-place indication and the opening indication value of the program control intermediate interface in real time, simulates the action of the field equipment and transmits a feedback signal to the wind tunnel control program through the program control intermediate interface;
for the field devices which are not selected in the step a, the wind tunnel control program transmits opening or closing commands to the actual output interfaces of the control modules corresponding to the field devices through the program control intermediate interfaces, the field devices are driven to execute corresponding opening or closing actions, and meanwhile, the actual input interfaces transmit read state parameters of the field devices to the program control intermediate interfaces and further feed back the state parameters to the wind tunnel control program;
d. c, the wind tunnel control program drives the control modules of the field devices one by one according to the time sequence and logic interlocking conditions of the test flow and the working process of the step c to obtain feedback signals until the 'hybrid simulation' of the test flow is finished;
e. the test responsible person and the software engineer readjust the test flow and the wind tunnel control program according to the simulation result of the hybrid simulation until the time sequence and logic interlocking conditions in the test flow meet the test requirements;
f. setting the mode of a wind tunnel control program to be 'real operation' by an operator through an upper computer; for the field device selected in the step a, the wind tunnel control program controls the corresponding variable of the intermediate interface according to the output signal of the actual input/output interface latched in the step c by the back-writing program; then restoring the connection between the program control intermediate interface and the actual input/output interface; at this time, the program control intermediate interface signal, the actual input/output interface signal and the state of the field device of the control module of the selected field device in the step a are consistent and are the states before simulation;
g. after the hybrid simulation is finished, the wind tunnel control program enters an actual operation state, the connection between program control intermediate interfaces of all field device control modules and actual input and output interfaces is switched on, and when the program control intermediate interfaces receive command signals for opening and closing, the field devices are immediately driven to execute corresponding actions; and reading the actual in-place opening and closing and opening related state parameters of the field equipment in real time, and feeding back the state parameters to the wind tunnel control program.
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