CN114488844B - Three-level bidirectional DC-DC charger semi-physical test platform and test method - Google Patents
Three-level bidirectional DC-DC charger semi-physical test platform and test method Download PDFInfo
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- CN114488844B CN114488844B CN202111594636.XA CN202111594636A CN114488844B CN 114488844 B CN114488844 B CN 114488844B CN 202111594636 A CN202111594636 A CN 202111594636A CN 114488844 B CN114488844 B CN 114488844B
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B17/00—Systems involving the use of models or simulators of said systems
- G05B17/02—Systems involving the use of models or simulators of said systems electric
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
- G05B23/0213—Modular or universal configuration of the monitoring system, e.g. monitoring system having modules that may be combined to build monitoring program; monitoring system that can be applied to legacy systems; adaptable monitoring system; using different communication protocols
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- Charge And Discharge Circuits For Batteries Or The Like (AREA)
Abstract
The invention relates to a performance verification method of a bidirectional DC-DC (direct current-direct current) charger controller, in particular to a three-level bidirectional DC-DC charger semi-physical test platform and a test method, wherein the test platform comprises a simulator, a control unit and a conditioning adaptation unit, the simulator is used for constructing a main circuit for simulating the three-level DC-DC bidirectional charger, and corresponding analog quantity, pulse feedback and digital quantity feedback are output according to input digital quantity commands and pulses; the control unit outputs a digital quantity command and outputs a pulse signal according to the received analog quantity, pulse feedback and digital quantity feedback; the conditioning and adapting unit is used for performing signal conversion conditioning so as to adapt to hardware channels of the simulator and the control unit. The three-level bidirectional DC-DC charger semi-physical test platform and the test method can verify the functions and performances of hardware and software of a control unit at low cost, analyze the influence of main circuit parameters on a system, and conveniently set different working conditions and verify a control algorithm.
Description
Technical Field
The invention relates to a performance verification method of a bidirectional DC-DC (direct current-direct current) charger controller, in particular to a three-level bidirectional DC-DC charger semi-physical test platform and a test method.
Background
Based on the requirements of green, energy-saving and environment-friendly of rail transit in China, the three-level technology is more and more valued because of the advantage of reducing the voltage stress of a switching device, and is rapidly developed and applied. The bidirectional DC-DC charger is a part of a train auxiliary system and can charge a storage battery or supply power to the train auxiliary system through the storage battery. And the three-level technology is applied to the charger, so that the switching frequency can be increased, and the voltage level of a switching device can be reduced.
In order to verify the functions and performances of the control unit of the charger to the greatest extent, a main circuit mathematical model with higher precision is required to be built, but the circuit of the full-material-object platform is complex, the building period is long, and more manpower is required; and the test period is long, the labor, the energy consumption and the device are damaged, and the cost is high. Some special conditions are not well realized or destroyed when realized in practice. The semi-physical simulation test provides convenience for the test of the control unit, shortens the debugging period and reduces the test cost.
Disclosure of Invention
The invention provides a semi-physical test platform and a test method of a three-level bidirectional DC-DC (direct current-direct current) charger. The method solves the problems of long construction period and high cost of the full-object test platform. And the fault condition simulation of the sensor can be realized without damaging the actual sensor, and the fault protection function of the control strategy is verified.
The invention is realized by adopting the following technical scheme: the three-level bidirectional DC-DC charger semi-physical test platform comprises a simulator, a control unit and a conditioning adaptation unit, wherein the simulator is used for constructing a main circuit for simulating the three-level DC-DC bidirectional charger and outputting corresponding analog quantity, pulse feedback and digital quantity feedback according to input digital quantity commands and pulses; the control unit outputs a digital quantity command and outputs a pulse signal according to the received analog quantity, pulse feedback and digital quantity feedback; the conditioning and adapting unit is used for performing signal conversion conditioning so as to adapt to hardware channels of the simulator and the control unit.
The three-level bidirectional DC-DC charger semi-physical test platform comprises a real-time simulation board card, a digital measurement board card and an analog measurement board card, and the board card interface configuration and information transmission are realized through a CPU; meanwhile, the simulation process is monitored by the upper computer software, parameters can be configured on line, and process data recording and storage are completed.
The control unit is a real object and comprises a DSP, an analog sampling interface circuit, a switch sampling circuit, a switch output circuit, a PWM driving circuit, a PWM feedback circuit, a control power supply, an Ethernet and the like; the start and stop of the main circuit are controlled through control logic and software programs, so that the charge and discharge functions of the three-level DC-DC bidirectional charger are realized, and meanwhile, the protection of the power device is considered.
The test method of the three-level bidirectional DC-DC charger semi-physical test platform comprises the following steps of:
1) Charging condition
After a semi-physical test platform of the three-level DC-DC bidirectional charger is built, a main circuit model is downloaded to a real-time simulation board card of a simulator, and upper computer software gives input voltage U dc The method comprises the steps that S1-S4 pulse feedback is 0, a voltage signal and a pulse feedback signal are output by a simulation board card in real time, the signals are input to a control unit through a conditioning adaptation unit, the control unit receives input voltage and pulse feedback through an analog sampling interface circuit and a PWM feedback circuit, a switch output circuit sends a precharge contactor closing command, the command is input to a simulation machine model after signal level conversion through the conditioning adaptation unit, a digital quantity signal is fed back by a digital quantity board card after the precharge contactor in a precharge loop is closed, the precharge loop obtains intermediate voltage according to calculation, the real-time simulation board card outputs the intermediate voltage signal and then is fed to the control unit through the conditioning adaptation unit, a main contactor closing command is sent out after the control unit detects that the intermediate voltage Uo is larger than or equal to a first set value, the main contactor closing command is input to the simulation machine after the main contactor is closed, the digital quantity signal is fed back by the digital quantity board card after the intermediate voltage Uo is larger than or equal to a second set value, a driving circuit sends a pulse S1 and a pulse S4 after the intermediate voltage Uo is larger than or equal to a second set value, the pulse is input to the simulation board after the intermediate voltage is subjected to the conditioning adaptation unit, and the simulation board outputs corresponding voltage and PWM is capable of outputting real-time voltage and corresponding voltage and PWM;
2) Discharge condition of
After a three-level DC-DC bidirectional charger semi-physical test platform is built, a main circuit model is downloaded to a simulator real-time simulation board card, upper computer software gives battery voltage, S1-S4 pulse feedback is 0, the simulator outputs an output voltage signal and a pulse feedback signal through the real-time simulation board card, the signals are input to a control unit through a conditioning adaptation unit, the control unit receives input voltage and pulse feedback through an analog sampling interface circuit and a PWM feedback circuit, a switch output circuit sends a precharge contactor closing command, the command is input to the simulator model after the signal level conversion through the conditioning adaptation unit, the precharge contactor in the precharge circuit is closed, a digital quantity signal is fed back by a digital quantity board card, the precharge circuit obtains intermediate voltage according to calculation, the real-time simulation board card outputs the intermediate voltage signal and then sends a main contactor closing command through a signal conditioning adaptation unit after the control unit detects that the intermediate voltage Uo is more than or equal to a first set value, the main contactor closing command is input to the simulator model after the main contactor is closed, the digital quantity signal is fed back by the digital quantity signal is sent through the conditioning adaptation unit after the digital quantity signal is more than or equal to a second set value, and the simulation board card receives the corresponding pulse feedback signal after the intermediate voltage is more than or equal to a second set value, and the simulation board card is output to the corresponding simulation board card after the S2 is subjected to the set value is equal to the second set value and the simulation signal is subjected to the real-time simulation signal is output to the simulation board 2.
According to the test method of the three-level bidirectional DC-DC charger semi-physical test platform, a sensor module is arranged in a main circuit model, x is input, y is output, the relation of y=kx+b, and k and b can be modified on line through upper computer software; when the simulator model and the control unit perform semi-physical joint debugging test, the actual sensor faults can be conveniently simulated through setting k and b, so that the simulation of the change condition of each voltage and each current of the main circuit under the sensor fault working condition and the verification of the protection function of the control unit are realized.
According to the test method of the three-level bidirectional DC-DC charger semi-physical test platform, the capacitance, resistance and inductance parameters of the main circuit in the model can be configured on line in the upper computer, so that the system matching relation of the main circuit parameters can be verified conveniently in real time, and the influence of certain parameter change on the system is analyzed.
According to the test method of the three-level bidirectional DC-DC charger semi-physical test platform, the main circuit model is built based on the Xilinx module in the MATLAB, and then compiled and downloaded to the simulator to simulate the board card in real time.
The three-level bidirectional DC-DC charger semi-physical test platform and the test method can verify the functions and performances of hardware and software of a control unit at low cost, analyze the influence of main circuit parameters on a system, and conveniently set different working conditions and verify a control algorithm.
Drawings
Fig. 1 is a schematic diagram of a semi-physical test platform of a three-level DC-DC bidirectional charger.
Fig. 2 is a block diagram of a simulator.
Fig. 3 is a block diagram of a conditioning adaptation unit.
Fig. 4 is a three-level DC-DC bi-directional converter main circuit.
Detailed Description
The semi-physical test platform of the three-level DC-DC bidirectional charger has a structure shown in figure 1, and the simulator is used for constructing a main circuit of the simulation three-level DC-DC bidirectional charger and outputting corresponding analog quantity, pulse feedback and digital quantity feedback according to input digital quantity commands and pulses. The control unit outputs a digital quantity command, and outputs a pulse signal according to the received analog quantity, pulse feedback and digital quantity feedback. The conditioning and adapting unit is used for performing signal conversion conditioning so as to adapt to hardware channels of the simulator and the control unit.
(1) Emulation machine
The structural block diagram of the simulator is shown in fig. 2, the simulator comprises a real-time simulation board card (FPGA), a digital measuring board card and an analog measuring board card, the simulator is arranged on a back plate of a chassis, the board cards are mutually independent and can be independently plugged and pulled out, and the configuration of a board card interface and information transmission are realized through a CPU. Meanwhile, the simulation process can be monitored by the upper computer software, parameters are configured on line, and process data are recorded and stored.
(2) Conditioning adaptation unit
The conditioning adaptation unit can convert the output signal of the simulator into the receivable signal of the control unit, such as analog quantities of main circuit voltage, current and the like, and also can convert the output signal of the control unit into the receivable signal of the simulator, such as pulse, contactor command and the like.
(3) Control unit
The control unit is a real object and consists of a DSP, an analog sampling interface circuit, a switch sampling circuit, a switch output circuit, a PWM driving circuit, a PWM feedback circuit, a control power supply, an Ethernet and the like. The start and stop of the main circuit are controlled through control logic and software programs, so that the charge and discharge functions of the three-level DC-DC bidirectional charger are realized, and meanwhile, the protection of the power device is considered.
Examples of the embodiments
The main circuit topology of the three-level DC-DC bidirectional charger is shown in fig. 4, and the input side is composed of two absorption capacitors C 1 、C 2 And voltage equalizing slow-release resistor R 1 、R 2 Is composed of four switch tubes S 1 ～S 4 To the filter inductance L 1 、L 2 And the filter capacitor C and the slow-release resistor R are connected to the output side and then connected with the battery through the pre-charge loop. Wherein AK is a precharge contactor, CHR is a precharge resistor, and K is a main contactor.
1) Charging condition
After a semi-physical test platform of the three-level DC-DC bidirectional charger is built, a main circuit model is downloaded to a real-time simulation board card of a simulator, and upper computer software gives input voltage U dc The simulation machine outputs voltage signals and pulse feedback signals through a real-time simulation board card, the signals are input to a control unit through a conditioning adaptation unit, the control unit receives input voltages and pulse feedback through an analog sampling interface circuit and a PWM feedback circuit, a switch output circuit sends out a precharge contactor closing command (digital quantity command) after receiving the input voltages and the pulse feedback, the command is input to a simulation machine model after being subjected to signal level conversion through the conditioning adaptation unit, the precharge contactor in a precharge circuit is closed and then fed back by the digital quantity board card to the digital quantity signal, the precharge circuit obtains intermediate voltages according to calculation, the real-time simulation board card outputs the intermediate voltage signals and then is sent to the control unit through the conditioning adaptation unit, the control unit sends out a main contactor closing command after detecting the intermediate voltages Uo is more than or equal to 600V, the main contactor closing command is also input to the simulation machine model after being subjected to the conditioning adaptation unit, the main contactor is closed, the digital quantity signals are fed back by the digital quantity board card, the driving circuit sends out pulses S1 and S4 after waiting until the intermediate voltages Uo is more than or equal to 950V,pulse is input into the simulator model after being conditioned by the adapting unit, and the simulator simulates the board card in real time to output corresponding intermediate voltage Uo and absorption capacitance C 1 、C 2 Voltage U 1 、U 2 Inductor current i L Charging current i battery And input side current i dc . Through rapid signal transmission, closed-loop real-time simulation of the simulator and the control unit is established, and the correctness of the control strategy under the charging working condition and the steady-state and dynamic performances can be verified.
2) Discharge condition of
After a semi-physical test platform of the three-level DC-DC bidirectional charger is built, the main circuit model is downloaded to a real-time simulation board card of the simulator. The upper computer software gives a battery voltage of 1020V-1500 VDC, S1-S4 pulse feedback is 0, the simulator outputs an output voltage signal and a pulse feedback signal through a real-time simulation board card, the signals are input into a control unit through a conditioning adaptation unit, the control unit receives the input voltage and the pulse feedback through an analog sampling interface circuit and a PWM feedback circuit, a switch output circuit sends a precharge contactor closing command, the command is input into a simulator model after the signal level is converted through the conditioning adaptation unit, a digital quantity board card feeds back a digital quantity signal after the precharge contactor in the precharge loop is closed, the precharge loop obtains an intermediate voltage according to calculation, the real-time simulation board card outputs the intermediate voltage signal and then sends the intermediate voltage signal to the control unit through the signal conditioning adaptation unit, the control unit sends a main contactor closing command after detecting the intermediate voltage Uo is more than or equal to 600V, the main contactor closing command is input into the simulator model after the main contactor is closed, the digital quantity signal is fed back through the digital quantity board card after the intermediate voltage is equal to the intermediate voltage U950V, the pulse S2 and the pulse S3 is sent after the intermediate voltage is equal to the digital quantity signal, and the pulse is input into the simulator model after the intermediate voltage Uo is more than or equal to the corresponding to the capacitor C, and the capacitor C is output to the simulator after the intermediate voltage is equal to and equal to the corresponding to the capacitor C 1 、C 2 Voltages U1, U2, inductor current i L Discharge current i' battery And input side current i dc . Through rapid signal transmission, a closed loop real-time simulation of the simulator and the control unit is established, and the discharge working condition can be verifiedThe correctness of the lower control strategy and the steady state and dynamic performance.
3) Sensor fault simulation
The model is provided with a sensor module, wherein the input x and the output y are related to y=kx+b, k and b, and the sensor module can be modified on line through upper computer software. When the simulator model and the control unit perform semi-physical joint debugging test, the actual sensor faults can be conveniently simulated through setting k and b, so that the simulation of the change condition of each voltage and each current of the main circuit under the sensor fault working condition and the verification of the protection function of the control unit are realized.
4) Analysis of the influence of main circuit parameters on a system
The capacitance, resistance and inductance parameters of the main circuit in the model can be configured in an upper computer on line, so that the system matching relation of the main circuit parameters can be conveniently verified in real time, and the influence of certain parameter change on the system is analyzed.
The three-level bidirectional DC-DC charger semi-physical test platform has the following beneficial effects:
1) The function and performance test of the control unit can be realized;
2) The test period is shortened, and the cost of labor, materials and time is reduced;
3) The sensor fault can be simulated without damage, and the control unit protection logic is verified;
4) The main circuit parameters can be modified on line, and the influence of a certain parameter change on the system is analyzed.
Claims (4)
1. A three-level bidirectional DC-DC charger semi-physical test platform is characterized in that: the device comprises a simulator, a control unit and a conditioning adaptation unit, wherein the simulator is used for constructing a main circuit of an analog three-level DC-DC bidirectional charger and outputting corresponding analog quantity, pulse feedback and digital quantity feedback according to input digital quantity commands and pulses; the control unit outputs a digital quantity command and outputs a pulse signal according to the received analog quantity, pulse feedback and digital quantity feedback; the conditioning adaptation unit is used for performing signal conversion and conditioning so as to adapt hardware channels of the simulation machine and the control unit, wherein the simulation machine comprises a real-time simulation board card, a digital measuring board card and an analog measuring board card, and the configuration of a board card interface and the information transmission are realized through a CPU; meanwhile, the simulation process is monitored by the upper computer software, parameters are configured on line, process data are recorded and stored, and the control unit is a real object and comprises a DSP, an analog sampling interface circuit, a switch sampling circuit, a switch output circuit, a PWM driving circuit, a PWM feedback circuit, a control power supply and an Ethernet; the start and stop of the main circuit are controlled through control logic and software programs, so that the charge and discharge functions of the three-level DC-DC bidirectional charger are realized, and meanwhile, the protection of the power device is considered;
the test method of the platform comprises the following steps:
1) Charging condition
After a semi-physical test platform of the three-level DC-DC bidirectional charger is built, a main circuit model is downloaded to a real-time simulation board card of a simulator, and upper computer software gives input voltageU dc S1-S4 pulse feedback is 0, the simulator outputs voltage signals and pulse feedback signals through the real-time simulation board card, the signals are input to the control unit through the conditioning adaptation unit, the control unit receives the input voltage and the pulse feedback through the analog sampling interface circuit and the PWM feedback circuit, the switch output circuit sends out a precharge contactor closing command, the command is input to the simulator model after being converted in signal level through the conditioning adaptation unit, the precharge contactor in the precharge circuit is fed back to a digital quantity signal through the digital quantity board card after being closed, the precharge circuit obtains intermediate voltage according to calculation, the real-time simulation board card outputs the intermediate voltage signals and then the intermediate voltage signals are fed to the control unit through the conditioning adaptation unit, and the control unit detects the intermediate voltageUAfter o is more than or equal to a first set value, a main contactor closing command is sent out, the main contactor closing command is input into a simulator after being subjected to conditioning and adapting units, a digital quantity signal is fed back by a digital measuring board card after the main contactor is closed, and the intermediate voltage is reachedUAfter o is more than or equal to a second set value, the PWM driving circuit sends out a pulse S1 and a pulse S4, the pulse is also input into the simulator after passing through the conditioning adaptation unit, and the simulator simulates the board card in real time to output corresponding voltage and current;
2) Discharge condition of
After a semi-physical test platform of the three-level DC-DC bidirectional charger is built, main electricity is suppliedThe method comprises the steps that a path model is downloaded to a real-time simulation board of a simulator, upper computer software gives battery voltage, S1-S4 pulse feedback is 0, the simulator outputs voltage signals and pulse feedback signals through the real-time simulation board, the signals are input to a control unit through a conditioning adaptation unit, the control unit receives input voltages and pulse feedback through an analog sampling interface circuit and a PWM feedback circuit, a switch output circuit sends out a precharge contactor closing command, the command is converted in signal level through the conditioning adaptation unit and then is input to the simulator model, a precharge contactor in a precharge loop is closed and then fed back to a digital quantity signal through a digital board, the precharge loop obtains intermediate voltage according to calculation, the real-time simulation board outputs the intermediate voltage signals and then is supplied to the control unit through the conditioning adaptation unit, and the control unit detects the intermediate voltageUoAfter the first set value is not less than the first set value, a main contactor closing command is sent out, the main contactor closing command is input into a simulator model after being subjected to conditioning and adapting units, a digital quantity signal is fed back by a digital measuring board card after the main contactor is closed, and the intermediate voltage is reachedUAnd after o is more than or equal to a second set value, sending out a pulse S2 and a pulse S3, and inputting the pulse into a simulation machine model after the pulse passes through the conditioning adaptation unit, wherein the simulation machine can output corresponding voltage and current in real time by simulating the board card.
2. The three-level bidirectional DC-DC charger semi-physical test platform of claim 1, wherein: the main circuit model is provided with a sensor module, wherein the input x and the output y are related to y=kx+b, and k and b can be modified on line through upper computer software; when the simulator model and the control unit perform semi-physical joint debugging test, the actual sensor faults can be conveniently simulated through setting k and b, so that the simulation of the change condition of each voltage and each current of the main circuit under the sensor fault working condition and the verification of the protection function of the control unit are realized.
3. The three-level bidirectional DC-DC charger semi-physical test platform according to claim 1 or 2, wherein the semi-physical test platform is characterized in that: the capacitance, resistance and inductance parameters of the main circuit in the model can be configured in an upper computer on line, so that the system matching relation of the main circuit parameters can be conveniently verified in real time, and the influence of certain parameter change on the system is analyzed.
4. The three-level bidirectional DC-DC charger semi-physical test platform according to claim 1 or 2, wherein the semi-physical test platform is characterized in that: the main circuit model is built based on an Xilinx module in MATLAB, compiled and downloaded to a real-time simulation board card of a simulator.
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