CN114371012A - Engine performance measurement and control system and method - Google Patents
Engine performance measurement and control system and method Download PDFInfo
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- G01M15/00—Testing of engines
- G01M15/04—Testing internal-combustion engines
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Abstract
The invention discloses a system and a method for measuring and controlling the performance of an engine, wherein the system comprises: the system comprises a PC (personal computer), a router, remote control terminal equipment, an ET5100 main control system and an engine performance measurement and control module, wherein the engine performance measurement and control module is used for acquiring engine performance data; the ET5100 master control system is in bidirectional communication with the engine performance measurement and control module and receives engine performance data uploaded by the engine performance measurement and control module; the remote control terminal equipment is in mutual communication with a PC through a router, an ET5000 system is installed in the PC, the ET5000 system is in mutual communication with an ET5100 main control system through Ethernet, and a real-time operating system is embedded in a host of the PC. The invention is applied to the TwinCAT real-time system, so that the internal programs of control, acquisition, calculation and the like can complete synchronous operation.
Description
Technical Field
The invention relates to the technical field of engine testing, in particular to an engine performance measurement and control system and method.
Background
In the process of producing the engine by each large engine manufacturer, in order to ensure that the produced engine meets the product quality requirement, the engine needs to be subjected to comprehensive performance test so as to detect whether the performance of the motor is qualified.
With the development of automobile technology, the application of modern electronic technology to engines is changing day by day. After the electronic injection technology is applied to automobiles, electronic controllers and various electronic sensors are used in large quantity, and the maintenance of the novel automobile with electronic injection is not possible at all if a plurality of screwdrivers and a plurality of wrenches are used for automobile maintenance. Therefore, the automobile diagnostic instrument becomes a necessary instrument for repairing the automobile, and the evaluation of the performance of the engine through the diagnostic instrument becomes possible. At present, the performance of the engine is detected by a large device of a whole set of hardware equipment and software, and the device is called as an engine comprehensive performance detector. The engine comprehensive performance detector is equivalent to an electrocardiograph of an automobile engine, can detect and diagnose various parameters and faults of the dynamic operation of the engine, and then achieves the purpose of repairing the engine through maintenance and adjustment. However, the engine comprehensive performance detector is high in purchase and installation cost, needs to be installed at a fixed position, and cannot be moved for use. The engine comprehensive performance detector has higher purchase and installation cost, occupies a large amount of space and cannot be used movably.
The invention patent application with the application number of CN202110770448.1 provides a method and a system for testing the performance of an engine. The method comprises the following steps: recording engine data of a normal vehicle through a diagnostic instrument; recording the same engine data for the vehicle to be tested under the same conditions; and comparing the two groups of data graphically through a diagnostic instrument to obtain the difference between the engine performance of the vehicle to be tested and the normal vehicle. The prior art has the following disadvantages: at present, a master control system mainly adopts control instrument equipment made in a single chip microcomputer mode, has no real-time performance, cannot perform functions of synchronous acquisition and the like, and cannot truly reflect the real efficiency value at the moment of recording. At present, the main control equipment and other sub-equipment adopt an analog quantity mode to control input and output. The communication instrument adopts an RS232 communication mode, and has the phenomena of low transmission rate, easy interference and the like. The control mode PID adjustment adopts a potentiometer mode, and the operation is relatively responsible. The current system control modes are few, and particularly the road condition making mode can not be basically finished. Each mode can only be switched undisturbed under specific conditions.
Disclosure of Invention
The invention aims to overcome the defects of the prior art, provides a system and a method for measuring and controlling the performance of an engine, and aims to solve the problems that a master control system in the prior art mainly adopts a single-chip mode to control instrument equipment, has no real-time performance, cannot perform functions such as synchronous acquisition and the like, and cannot truly reflect the real efficiency value at the moment of recording.
The purpose of the invention is realized by the following technical scheme:
engine performance observes and controls system, it includes: the system comprises a PC (personal computer), a router, remote control terminal equipment, an ET5100 main control system and an engine performance measurement and control module, wherein the engine performance measurement and control module is used for acquiring engine performance data; the ET5100 master control system is in bidirectional communication with the engine performance measurement and control module, receives engine performance data uploaded by the engine performance measurement and control module, and sends a control instruction to the engine performance measurement and control module; the remote control terminal equipment is in mutual communication with a PC through a router, an ET5000 system is installed in the PC, the ET5000 system is in mutual communication with an ET5100 main control system through Ethernet, and a real-time operating system and an EtherCAT real-time industrial bus are embedded in a host of the PC.
Further, the ET5100 master control system comprises a controller, a core function module, an extended function module and an HMI module, wherein the controller, the core function module and the extended function module are connected through an EtherCAT real-time industrial bus, and the controller, the core function module and the HMI module are connected through RS 485.
Furthermore, the engine performance measurement and control module comprises a frequency converter, a torque and rotating speed measurement module, an oil consumption meter and a driving instrument, and the engine performance measurement and control module is connected with the ET5100 master control system through EtherCAT and used for synchronously acquiring engine performance data.
Furthermore, the router is connected with the remote control terminal device through a cloud server.
Further, the PC is provided with a Willon touch screen.
The engine performance measurement and control method comprises the following steps:
s1: supplying oil to the engine, and simultaneously controlling the throttle opening to accelerate the engine to the normal operation;
s2: after the engine normally runs, carrying out loading control and parameter measurement by using an electric dynamometer;
s3: starting an ET4900-LQY engine coolant constant temperature system, an ET4900-JY engine oil constant temperature system and an ET4900-ZL engine inter-cooling constant temperature system for ensuring the normal operation of the engine;
s4: an ET4300 data acquisition module is configured to acquire parameters of the engine;
s5: the master control system sends a control instruction to the electric dynamometer, and the working and power generation states of the electric dynamometer are fed back to the power grid through the operation of the controller.
Further, in S1, the engine ET4900-RY supplies oil to the engine, and the ET4600-SF accelerator actuator actuates the accelerator opening of the engine.
Further, the S2 further includes: the system carries out loading test on the accelerator opening of the engine and the loading opening of the dynamometer through the master control system, and the parameters comprise: torque, rotational speed.
Further, the collecting of the engine parameter in S4 includes: and collecting the pressure, the temperature and the flow of the engine.
Further, in S5, specifically, the method includes: the system ET5100 sends an instruction to the electric dynamometer controller, the electric dynamometer controller outputs the instruction to the electric dynamometer through IGBT control, and the working and power generation states of the electric dynamometer are fed back to a power grid through operation and power generation of the controller.
The invention has the beneficial effects that:
1. the adopted electric dynamometer has fast test speed response, and the electric dynamometer feeds back to the power grid, belongs to generator equipment, and is superior to other types of dynamometers, such as a magnetic powder dynamometer, an eddy current dynamometer, a water conservancy dynamometer and the like.
2. The frame design adopts a modular design, each sub-device can operate independently, and the data is exchanged with the main control device in a full digital communication mode, so that the problem that the data acquisition and transmission of analog quantity are interfered is solved.
3. The main control system can set alarm monitoring and alarm control of each subsystem according to the alarm of the system.
4. The main control system adopts a real-time system, and has the characteristics of high operation speed, strong anti-interference capability and the like.
5. ET5100 expansion ability is strong, adopts open EtherCAT bus standard, and test system function upgrade or performance promotion become very simple. German Fufu has a large number of industrial controllers and terminal modules for direct use, including data acquisition, servo control and communication. Moreover, brand manufacturers such as various global big data acquisition, frequency converters, servo controllers and human-computer interaction products support EtherCAT bus communication.
6. The human-computer interaction adopts 8-inch TFT high-definition color liquid crystal display, and the international first Grayhill high-precision photoelectric encoder knob makes the human-computer interaction simple and comfortable.
7. All data acquisition modules provide an accurate time base for the TwinCAT system, programs can be executed with the highest certainty, the real-time load rate on the PC can be set by the TwinCAT independently of other processor tasks, thereby realizing the preset operation performance, the TwinCAT system can display the system load of the running programs, and the critical value of the load can be set so as to ensure the specified operation capability for the running programs and the Windows NT/2000/XP.
8. The method is applied to a TwinCAT real-time system, so that internal programs such as control, acquisition, calculation and the like can finish synchronous operation, namely, the test of the unity of real-time clocks, high speed or high synchronism is particularly applied to tested pieces such as an engine, a gearbox, a motor and the like.
9. And (3) torque measurement: the method is compatible with various sensors, is compatible with torque sensors with frequency pulse less than or equal to 1MHz, a strain resistance bridge, 0-10V voltage, phase difference signals and other signal output types, and has the following sampling rate: 1 Hz-1 kHz, measurement precision: . + -. 0.1% F.S (1kH samples).
10. And (3) measuring the rotating speed: compatible multiple sensor, rotational speed sensor such as compatible encoder signal, hall and photoelectric switch signal, CAN or RS232 communication, sampling rate: 1 Hz-1 kHz (specially up to 10kHz) measurement precision: . + -. 0.1% F.S (1kH samples).
11. The integrated 2-way PID operation can be run simultaneously, and has M/P, M/n, n/P, n/M and other modes for selection. The PID coefficient is adjustable in 0-31 level.
12. Multiple control modes are integrated inside, and the rotating speed and the load are regulated and controlled by adopting a digital segmented double-loop PID. The undisturbed switching of various control characteristics meets the test of various power systems such as an engine, a motor and the like.
Drawings
Fig. 1 is a schematic view of the overall structure of the present invention.
Detailed Description
In order to more clearly understand the technical features, objects, and effects of the present invention, embodiments of the present invention will now be described with reference to the accompanying drawings.
In this embodiment, as shown in fig. 1, the engine performance measurement and control system includes: the system comprises a PC (personal computer), a router, remote control terminal equipment, an ET5100 main control system and an engine performance measurement and control module, wherein the engine performance measurement and control module is used for acquiring engine performance data; the ET5100 master control system is in bidirectional communication with the engine performance measurement and control module, receives engine performance data uploaded by the engine performance measurement and control module, and sends a control instruction to the engine performance measurement and control module; the remote control terminal equipment is in mutual communication with a PC through a router, an ET5000 system is installed in the PC, the ET5000 system is in mutual communication with an ET5100 main control system through Ethernet, and a real-time operating system and an EtherCAT real-time industrial bus are embedded in a host of the PC.
The working principle of the system equipment and the working process thereof;
the host module is developed for a Beifu embedded PLC controller, and a real-time operating system and an EtherCAT real-time industrial bus are embedded.
By adopting the industry leading EtherCAT communication bus technology, the test system is very simple to realize high-speed distributed control. And the Ethernet communication with the PC can be easily realized by EtherCAT or EtherNet/IP real-time Ethernet.
The working process is as follows: data acquisition + TwinCAT real-time system + ET5100 test program + data control output mode and the like.
Specifically, the technical advantages of the system and the technical problems to be solved;
1. ET5100 expansion ability is strong, adopts open EtherCAT bus standard, and test system function upgrade or performance promotion become very simple. German Fufu has a large number of industrial controllers and terminal modules for direct use, including data acquisition, servo control and communication. Moreover, brand manufacturers such as various global big data acquisition, frequency converters, servo controllers and human-computer interaction products support EtherCAT bus communication.
2. The human-computer interaction is displayed by adopting an 8-inch TFT high-definition color liquid crystal screen, and the international first Grayhill high-precision photoelectric encoder knob enables the human-computer interaction to be simple and comfortable;
3. the use of all data acquisition modules in the TwinCAT system provides an accurate time base with which programs can be executed with the highest certainty, independently of other processor tasks. The real-time load rate on the PC can be set with TwinCAT to achieve a predetermined operating performance. The TwinCAT system may display the system load of the running program. The load threshold value may be set so as to ensure a prescribed computing power for running the program and Windows NT/2000/XP.
4. The method is applied to a TwinCAT real-time system, so that internal programs such as control, acquisition, calculation and the like can finish synchronous operation, namely the real-time clock is unified, and high-speed or high-synchronism tests are particularly applied to tested pieces such as an engine, a gearbox, a motor and the like;
5. and (3) torque measurement: the sensor is compatible with various sensors, and is compatible with a torque sensor with frequency pulse less than or equal to 1MHz, a strain resistance bridge, voltage of 0-10V, phase difference signals and other signal output types. Sampling rate: 1 Hz-1 kHz, measurement precision: 0.1% F.S (1kH samples);
6. and (3) measuring the rotating speed: the sensor is compatible with various sensors, encoder signals, Hall and photoelectric switch signals, CAN or RS232 communication and other rotation speed sensors. Sampling rate: 1 Hz-1 kHz (specially up to 10kHz) measurement precision: 0.1% F.S (1kH samples);
7. the integrated 2-way PID operation can be run simultaneously, and has M/P, M/n, n/P, n/M and other modes for selection. The PID coefficient is adjustable in 0-31 level;
8. multiple control modes are integrated inside, and the rotating speed and the load are regulated and controlled by adopting a digital segmented double-loop PID. The undisturbed switching of various control characteristics meets the test of various power systems such as an engine, a motor and the like.
The control modes are as follows:
| pattern name | Function(s) |
| M/P | Dynamometer constant torque/drive (throttle) constant position mode |
| M/N | Dynamometer constant torque/drive constant speed mode |
| N/P | Dynamometer constant speed/drive constant position mode |
| N/M | Dynamometer constant speed/drive constant torque mode |
| M/L | Dynamometer constant torque/drive positioning rotation mode |
| L/M | Dynamometer positioning rotation/drive constant torque mode |
| X1/X2/X3 | Extended schema, defining schema by project requirement |
| S/P | Dynamometer whole vehicle simulation/drive constant position mode |
| S/V | Dynamometer whole vehicle simulation/drive constant vehicle speed mode |
| P/P | Dynamometer constant position/driving constant position mode |
| PANEL ON/OFF | Panel enable |
| RESET | Reset, go back to P/P mode, load and drive give 0% |
| BRAKE | Braking, returning to P/P mode, setting load at 30% and driving at 0% |
| LOAD ON/OFF | Start and stop of load dynamometer |
| DRIVE ON/OFF | Starting and stopping of driving equipment |
| Stop | Shutdown |
In this embodiment, the ET5100 master control system includes a controller, a core function module, an extended function module, and an HMI module, wherein the controller, the core function module, and the extended function module are connected by an EtherCAT real-time industrial bus, the controller, the core function module, and the HMI module are connected by an RS485, wherein the controller and the core function module include a CX9020, a communication coupling module, and an EtherCAT coupling module, and the extended function module includes an EtherCAT coupling module, an EtherCAT bridging module, an RTD temperature, a relay output module, and a can open coupling module.
In this embodiment, the engine performance measurement and control module includes a frequency converter, a torque and rotation speed measurement module, an oil consumption meter and a driver, and the engine performance measurement and control module is connected with the ET5100 master control system through EtherCAT for synchronous acquisition of engine performance data.
In this embodiment, the router and the remote control terminal device are connected through a cloud server.
In this embodiment, the PC is configured with a wilton touch screen.
The engine performance measurement and control method comprises the following steps:
s1: supplying oil to the engine, and simultaneously controlling the throttle opening to accelerate the engine to the normal operation;
s2: after the engine normally runs, carrying out loading control and parameter measurement by using an electric dynamometer;
s3: starting an ET4900-LQY engine coolant constant temperature system, an ET4900-JY engine oil constant temperature system and an ET4900-ZL engine inter-cooling constant temperature system for ensuring the normal operation of the engine;
s4: an ET4300 data acquisition module is configured to acquire parameters of the engine;
s5: the master control system sends a control instruction to the electric dynamometer, and the working and power generation states of the electric dynamometer are fed back to the power grid through the operation of the controller for power generation;
specifically, the working principle of the system equipment and the working process thereof are as follows:
1. the engine is started to supply oil to the engine ET4900-RY when the engine runs, and the ET4600-SF accelerator actuating mechanism executes the accelerator opening of the engine, so that the rotating speed of the engine is increased.
2. And loading the engine, and when the engine normally runs, carrying out loading control and torque and rotating speed measurement by the electric dynamometer. The system carries out loading test on the opening degree of an accelerator of the engine and the loading opening degree of the dynamometer through the master control system.
3. The operation of the system is guaranteed, and the ET4900-LQY engine coolant constant temperature system, the ET4900-JY engine oil constant temperature system and the ET4900-ZL engine inter-cooling constant temperature system guarantee the normal operation of the engine according to the requirements of the engine.
4. And the data acquisition module is configured with an ET4300 data acquisition module to acquire data of the pressure, the temperature, the flow and the like of the engine.
5. The engine is loaded, the system ET5100 sends an instruction to the electric dynamometer controller, the controller controls the output to the electric dynamometer to be loaded through the IGBT, and the electric dynamometer at the moment works and generates electricity, and the electricity is generated through the operation of the controller and fed back to a power grid.
The technical advantages of the system equipment and the technical problems to be solved;
1. the adopted electric dynamometer has fast test speed response, and the electric dynamometer feeds back to a power grid, belongs to generator equipment, and is superior to other types of dynamometers (magnetic powder dynamometer, eddy current dynamometer and water conservancy dynamometer).
2. The frame design adopts a modular design, each sub-device can operate independently, and data are exchanged with the main control device in an all-digital communication mode. The problem that data acquisition and transmission of analog quantity are interfered is solved.
3. The main control system can set alarm monitoring and alarm control of each subsystem according to the alarm of the system.
4. The main control system adopts a real-time system, and has the characteristics of high operation speed, strong anti-interference capability and the like.
In this embodiment, in S1, the engine ET4900-RY is used to supply oil to the engine, and the ET4600-SF accelerator actuator is used to execute the accelerator opening of the engine.
In this embodiment, the S2 further includes: the system carries out loading test on the accelerator opening of the engine and the loading opening of the dynamometer through the master control system, and the parameters comprise: torque, rotational speed.
In this embodiment, the collecting of the engine parameter in S4 includes: and collecting the pressure, the temperature and the flow of the engine.
In this embodiment, the step S5 specifically includes: the system ET5100 sends an instruction to the electric dynamometer controller, the electric dynamometer controller outputs the instruction to the electric dynamometer through IGBT control, and the working and power generation states of the electric dynamometer are fed back to a power grid through operation and power generation of the controller.
The foregoing shows and describes the general principles and broad features of the present invention and advantages thereof. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (10)
1. Engine performance observes and controls system, its characterized in that includes: the system comprises a PC (personal computer), a router, remote control terminal equipment, an ET5100 main control system and an engine performance measurement and control module, wherein the engine performance measurement and control module is used for acquiring engine performance data; the ET5100 master control system is in bidirectional communication with the engine performance measurement and control module, receives engine performance data uploaded by the engine performance measurement and control module, and sends a control instruction to the engine performance measurement and control module; the remote control terminal equipment is in mutual communication with a PC through a router, an ET5000 system is installed in the PC, the ET5000 system is in mutual communication with an ET5100 main control system through Ethernet, and a real-time operating system and an EtherCAT real-time industrial bus are embedded in a host of the PC.
2. The engine performance measurement and control system of claim 1, wherein the ET5100 master control system comprises a controller, a core function module, an extended function module and an HMI module, wherein the controller, the core function module and the extended function module are connected through an EtherCAT real-time industrial bus, and the controller, the core function module and the HMI module are connected through an RS 485.
3. The engine performance measurement and control system of claim 1, wherein the engine performance measurement and control module comprises a frequency converter, a torque and rotation speed measurement module, an oil consumption meter and a driving instrument, and the engine performance measurement and control module is connected with an ET5100 main control system through EtherCAT and used for synchronously acquiring engine performance data.
4. The engine performance measurement and control system according to claim 1, wherein the router is connected with the remote control terminal device through a cloud server.
5. The engine performance measurement and control system of claim 1, wherein the PC is configured with a Wirelon touch screen.
6. The engine performance measurement and control method is characterized by comprising the following steps:
s1: supplying oil to the engine, and simultaneously controlling the throttle opening to accelerate the engine to the normal operation;
s2: after the engine normally runs, carrying out loading control and parameter measurement by using an electric dynamometer;
s3: starting an ET4900-LQY engine coolant constant temperature system, an ET4900-JY engine oil constant temperature system and an ET4900-ZL engine inter-cooling constant temperature system for ensuring the normal operation of the engine;
s4: an ET4300 data acquisition module is configured to acquire parameters of the engine;
s5: the master control system sends a control instruction to the electric dynamometer, and the working and power generation states of the electric dynamometer are fed back to the power grid through the operation of the controller.
7. The engine performance measurement and control method according to claim 6, characterized in that in S1, the engine is supplied with oil through the engine ET4900-RY, and the accelerator opening of the engine is executed through an ET4600-SF accelerator execution mechanism.
8. The engine performance measurement and control method according to claim 6, wherein the step S2 further comprises: the system carries out loading test on the accelerator opening of the engine and the loading opening of the dynamometer through the master control system, and the parameters comprise: torque, rotational speed.
9. The engine performance measurement and control method according to claim 6, wherein the step of collecting the engine parameters in the step S4 includes: and collecting the pressure, the temperature and the flow of the engine.
10. The engine performance measurement and control method according to claim 6, wherein the step S5 specifically comprises: the system ET5100 sends an instruction to the electric dynamometer controller, the electric dynamometer controller outputs the instruction to the electric dynamometer through IGBT control, and the working and power generation states of the electric dynamometer are fed back to a power grid through operation and power generation of the controller.
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| CN109470485A (en) * | 2018-09-28 | 2019-03-15 | 中国地质大学（武汉） | A kind of CAN bus based engine pedestal integration test control system |
| CN111678703A (en) * | 2020-06-22 | 2020-09-18 | 陈剑辉 | Engine dynamometer control and data acquisition system |
| CN112631196A (en) * | 2020-12-25 | 2021-04-09 | 中国船舶重工集团公司第七0三研究所 | High-speed data acquisition and control system based on PLC |
| CN214584038U (en) * | 2021-03-05 | 2021-11-02 | 四川诚邦测控技术有限公司 | System based on engine performance test |
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