CN116341341B - Digital prototype and virtual sensing method thereof - Google Patents
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Abstract
The invention relates to a digital prototype and a virtual sensing method thereof. Wherein, the digital prototype includes: the system comprises a product information display module, a system performance model library, a component physical model library, a digital prototype dimension reduction module, a database, a physical prototype interface and a ground test system interface; the product information display module comprises a simulation/operation data receiving and transmitting sub-module and a data display sub-module; the system performance model library comprises a performance simulation sub-module, a model real-time sub-module and a performance data receiving and transmitting sub-module; the component physical model library comprises a multi-field simulation sub-module and a multi-field simulation data receiving and transmitting sub-module; the dimension reduction module of the digital prototype comprises a test data screening sub-module, a dimension reduction algorithm sub-module and a physical field data receiving and transmitting sub-module; the database comprises a simulation database and a test database. The problem that high-end equipment is difficult to monitor in the state in the operation and maintenance process, operation and maintenance data cannot be comprehensively acquired, and transmissible data are limited is solved.
Description
Technical Field
The invention relates to the technical field of digital twinning, in particular to a digital prototype and a virtual sensing method thereof.
Background
The digital twin is to create a virtual model of the physical entity in a digital mode, simulate the behavior of the physical entity in a real environment by means of data, and add or expand new capability for the physical entity by means of virtual-real interaction feedback, data fusion analysis, decision iteration optimization and the like; as a technology for fully utilizing models, data, intelligence and integrating multiple disciplines, digital twinning is oriented to the whole life cycle process of products, plays the role of bridges and ties for connecting physical world and information world, and provides more real-time, efficient and intelligent service; the digital prototype is the core of the digital twin technology, and mainly digitally describes the design scheme, manufacturing process, delivery state and the like of equipment in the overall design, manufacturing and delivery processes of the equipment, supports the development and production of the industrial department equipment, and guides design work in different stages of development by establishing different element models.
However, with the push of digital delivery, more digital prototypes need to be used by users at the operation and maintenance end to support the guidance of product operation and maintenance, but the current digital prototyping system has obvious defects on the support of the product operation and maintenance stage, and specifically includes: the running state of the product at the present stage can only acquire key information through a small number of sensors, so that the state information of the product is difficult to acquire comprehensively and the running state of the product cannot be monitored comprehensively and accurately; aiming at high-end equipment, the arrangement of the sensors can cause the reduction of the reliability of products, and the arrangement of the products can be influenced by the circuit layout; under the development trend of miniaturization and light weight, high-end equipment cannot effectively arrange sensors due to the constraints of installation positions and volume and mass; the high temperature and high pressure positions such as a high temperature combustion chamber and an ultrahigh pressure air entraining source cannot select a proper sensor due to the limitation of a measuring object, and a large amount of flow field, temperature field and pressure field data cannot be acquired through the sensor; the state information of the high-end equipment is often transmitted to an upper computer or a processor for storage and processing through hard wire or wireless communication, however, with the enhancement of the complexity of the whole machine, the communication protocol and the transmission channel are limited, and the independent transmission of a large amount of state information cannot be satisfied.
Disclosure of Invention
The invention aims to overcome the defects of the technology, and provides a digital prototype and a virtual sensing method thereof, which are used for solving the problems that high-end equipment is difficult to monitor in the operation and maintenance process, operation and maintenance data cannot be comprehensively acquired and transmissible data are limited.
In a first aspect, the present invention provides a digital prototype comprising: the system comprises a product information display module, a system performance model library, a component physical model library, a digital prototype dimension reduction module, a database, a physical prototype interface and a ground test system interface;
the product information display module comprises a simulation/operation data receiving and transmitting sub-module and a data display sub-module; the simulation/operation data receiving and transmitting sub-module receives real-time simulation information transmitted by the system performance model library, receives part physical field information transmitted by the digital prototype dimension reduction module, and receives state information and sensor information transmitted by the physical prototype, and simultaneously, the simulation/operation data receiving and transmitting sub-module transmits initial conditions and boundary constraints to the system performance model library and transmits the state information and the sensor information to the digital prototype dimension reduction module; the data display sub-module is used for loading and displaying the geometric form and the running state of the product;
the system performance model library comprises a performance simulation sub-module, a model real-time sub-module and a performance data receiving and transmitting sub-module; the performance simulation sub-module is used for carrying out product functional performance simulation and debugging and updating a system performance model; the model real-time submodule is used for carrying out real-time processing on the system performance model;
the component physical model library comprises a multi-field simulation sub-module and a multi-field simulation data receiving and transmitting sub-module; the multi-field simulation sub-module is used for performing simulation calculation of various physical fields of the product component;
the dimension reduction module of the digital prototype comprises a test data screening sub-module, a dimension reduction algorithm sub-module and a physical field data receiving and transmitting sub-module; the test data screening submodule is used for screening mass data of the database; the dimension reduction algorithm submodule is used for carrying out dimension reduction treatment on multiple types of physical field models in the component physical model library;
the ground test system comprises a system performance test and a component independent test;
the database comprises a simulation database and a test database; the simulation database stores finite element simulation data of multiple types of physical fields in a physical model base of the component; and the test database stores the data results of the independent tests of the components, and performs classified storage and management.
In some embodiments, the product information display module further comprises an instruction issuing sub-module; the instruction issuing sub-module issues a simulation operation instruction to the system performance model library.
In some embodiments, the model real-time submodule discretizes the system performance model according to the real control period of the physical prototype, so as to ensure that the system performance model and the physical prototype run in the same time scale.
In some embodiments, the performance data transceiver submodule is used for receiving the simulation instruction and the physical prototype sensor data transmitted by the product information display module, receiving the sensor measurement point information of the system performance test and receiving the model simulation data in the component physical model library.
In some embodiments, the multi-field simulation submodule includes a multi-class multi-field simulation environment including: flow field simulation, thermodynamic simulation, intensity simulation and electromagnetic field simulation.
In a second aspect, the present invention also provides a virtual sensing method as in the digital prototype of the first aspect, the virtual sensing method comprising the steps of:
s1: establishing a product information display module, and developing functions of a command issuing sub-module, a data receiving and transmitting sub-module and a product information display sub-module;
s2: introducing a system performance model into a system performance model library, and performing simulation calculation and real-time processing;
s3: introducing a product multi-class physical field finite element model into a component physical model library for simulation calculation;
s4: storing and calling the data in a database;
s5: in a dimension reduction module of the digital prototype, reducing the multiple types of physical field simulation models into a data model which can be synchronously solved with a system performance model;
s6: the physical prototype sends the running state information and the sensor information to the product information display module;
s7: the product information display module sends the state information to the system performance model library, and the system performance model library calculates the full state information of the physical prototype based on the state information and transmits the full state information of the physical prototype back to the product information display module;
s8: the product information display module sends the full-state information of the physical model machine to the dimension reduction module of the digital model machine for further calculation to obtain the physical field information of the core component, and returns the physical field information of the core component to the product information display module;
s9: in the product information display module, the full-state information of the physical prototype and the physical field information of the core component are displayed in a centralized way, and when the acquired information exceeds the normal operation threshold value of the product, an alarm instruction is sent and fault data are reported;
s10: and in the product information display module, comparing and displaying the sensor information with the full-state information of the physical prototype, setting a difference threshold, and when the difference threshold is exceeded, prompting that the accuracy of the virtual sensing system is insufficient, and carrying out factory return updating.
In some embodiments, step S1 comprises: s11: a development instruction issuing sub-module establishes a transmission interface for sending data and receiving data; s12: the method comprises the steps of linking an instruction issuing interface of a product information display module into a system performance model library, wherein the instruction is a start-stop instruction of a digital prototype; s13: respectively linking a data transmission interface of the product information display module to a system performance model library and a dimension reduction module of the digital sample machine; the system performance model library is used for storing the data interface types of the system performance model library, wherein the data interface types linked to the system performance model library are initial conditions and boundary conditions of simulation, and the data interface types linked to the digital prototype dimension reduction module are state information and sensor information of a physical prototype; s14: respectively linking the data receiving interfaces of the product information display module to a physical prototype, a system performance model library and a digital prototype dimension reduction module; the system comprises a physical model machine, a system performance model library, a physical model machine dimension reduction module, a system performance model library, a physical model machine dimension reduction module and a physical model machine dimension reduction module, wherein the type of a data interface connected to the physical model machine is a digital quantity interface capable of receiving real-time acquisition data, the type of a data interface connected to the system performance model library is a full-state real-time simulation result, and the type of a data interface connected to the physical model machine dimension reduction module is a component physical field real-time simulation result; s15: according to the display requirement of the product information display module of the digital prototype system, developing data processing functions such as data processing, cloud drawing, state display, trend analysis and the like corresponding to the data types of the data receiving and transmitting submodule, and loading and displaying the geometric form and the running state of the product in the product information display module.
In some embodiments, step S2 comprises: s21: importing a system performance model supporting Matlab/Simulink and Amesim simulation environments into a system performance model library; s22: carrying out real-time processing on the system performance model, setting corresponding simulation step length according to the control requirement of a physical prototype by adopting fixed-step iterative computation by a solver, and ensuring that the convergence degree of fixed-step simulation and original variable-step simulation is consistent; s23: and carrying out two-round iterative updating on the one-dimensional performance model in the system performance model library, firstly receiving simulation data of the component physical model library, updating a simplified part in the performance model by utilizing the detailed simulation result, then receiving system performance test data, and carrying out proportional correction and iteration on the performance model according to the test data.
In some embodiments, step S3 comprises: s31: leading a finite element physical model supporting Fluent, CFX, mechanical and the like under ANSYS into a component physical model library to perform corresponding simulation calculation; s32: and uploading the simulation result of the component physical model library to a system performance model library through a data interface for iterating the model, and transmitting the simulation result obtained by the component physical model to a basic database for storage through a data transmission interface after classification.
In some embodiments, step S5 comprises: s51: invoking simulation data of multiple physical field models in a database; s52: establishing a data screening criterion, establishing evaluation indexes from four dimensions of model precision, model robustness, noise influence and calculation cost, and screening and cleaning simulation data samples in a database by adopting an optimal Latin hypercube algorithm function by utilizing a DOE test design method; s53: training simulation data samples screened by a DOE method by adopting a multi-layer neural network algorithm, obtaining a mapping relation between input characteristics and key performances of a multi-field model, and solidifying the trained neural network node parameters; s54: the test data in the database is called to carry out iterative correction on the established mapping relation, wherein a certain proportion of samples are selected as updating samples, and a certain proportion of samples are taken as verification samples so as to ensure the generalization degree of the mapping relation; s55: obtaining an optimal reduced-order data model under an error root mean square and model multidimensional evaluation system; s56: and solidifying the established optimal reduced-order data model in a dimension reduction module of the digital prototype.
The technical scheme provided by the invention has the following beneficial effects:
1. the digital prototype and the virtual sensing method thereof provided by the invention are oriented to high-end equipment, and can monitor the information in the whole state under the condition that only a small number of sensors are arranged in a mode of constructing the digital prototype, so that the reliability is ensured and the condition-dependent maintenance capability of the product is improved without increasing the sensors.
2. The digital prototype and the virtual sensing method thereof solve the problem that the state information is difficult to acquire due to space position and measurement limitation, and realize the monitoring and sharing of the global state information of high-end equipment.
3. According to the digital prototype and the virtual sensing method thereof, the prior model and the test data are utilized to synchronously perform model dimension reduction processing, and the quasi-real-time state can be updated according to the physical prototype data, so that the problem of poor synergy caused by product dissimilarity is solved.
4. According to the digital prototype and the virtual sensing method thereof, the performance model of the complex system is subjected to real-time and priori processing to obtain the consistency of the performance model with the time scale and the physical scale of the physical prototype, and the finite data acquisition of the physical prototype is combined to calculate the full-state performance information, so that the performance state monitoring function is realized.
5. According to the digital prototype and the virtual sensing method thereof, the component physical model is subjected to normalization processing, namely, each physical field model is unified into a quasi-real-time data model for sensing the state of the component by a model reduction technology based on simulation/test mixed data at the expense of certain simulation precision.
6. According to the digital prototype and the virtual sensing method thereof, data are collected in real time by using the physical prototype, the data are embedded into the system performance model library, iterative training and updating are carried out on the model, and the problem of insufficient state analysis accuracy caused by product anisotropy or performance degradation is solved.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.
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The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the disclosure and together with the description, serve to explain the principles of the disclosure.
Fig. 1 shows a schematic diagram of a digital prototype of the invention.
Detailed Description
The disclosure will now be discussed with reference to several exemplary embodiments. It should be understood that these embodiments are discussed only to enable those of ordinary skill in the art to better understand and thus practice the present disclosure, and are not meant to imply any limitation on the scope of the present disclosure.
As used herein, the term "comprising" and variants thereof are to be interpreted as meaning "including but not limited to" open-ended terms. The term "based on" is to be interpreted as "based at least in part on". The terms "one embodiment" and "an embodiment" are to be interpreted as "at least one embodiment. The term "another embodiment" is to be interpreted as "at least one other embodiment".
The embodiment of the invention discloses a digital prototype, which is characterized in that a digital prototype system supporting operation and maintenance is established, a virtual sensing method is utilized to realize the functions of monitoring the global real-time state of a product and analyzing data under the support of a limited physical sensor, the use boundary of the digital prototype is expanded, and the digital delivery of high-end equipment is supported.
As shown in fig. 1, the digital prototype includes: the system comprises a product information display module 101, a system performance model library 102, a component physical model library 103, a digital prototype dimension reduction module 104, a database 105, a physical prototype interface and a ground test system interface;
the product information display module 101 includes a simulation/operation data transceiving sub-module and a data display sub-module; the simulation/operation data receiving and transmitting sub-module receives real-time simulation information transmitted by the system performance model library 102, receives part physical field information transmitted by the digital prototype dimension reduction module 104, and receives state information and sensor information transmitted by the physical prototype, and simultaneously, the simulation/operation data receiving and transmitting sub-module transmits initial conditions and boundary constraints to the system performance model library 102 and transmits the state information and the sensor information to the digital prototype dimension reduction module 104; the data display sub-module is used for loading and displaying the geometric form and the running state of the product;
the system performance model library 102 comprises a performance simulation sub-module, a model real-time sub-module and a performance data receiving and transmitting sub-module; the performance simulation sub-module is used for carrying out product functional performance simulation and debugging and updating a system performance model; the model real-time submodule is used for carrying out real-time processing on the system performance model;
the component physical model library 103 comprises a multi-field simulation sub-module and a multi-field simulation data transceiver sub-module; the multi-field simulation sub-module is used for performing simulation calculation of various physical fields of the product component;
the digital prototype dimension reduction module 104 comprises a test data screening sub-module, a dimension reduction algorithm sub-module and a physical field data receiving and transmitting sub-module; the test data screening submodule is used for screening mass data of the database 105; the dimension reduction algorithm submodule is used for carrying out dimension reduction processing on the multi-class physical field model in the component physical model library 103;
the ground test system comprises a system performance test and a component independent test;
database 105 includes a simulation database and a trial database; the simulation database stores multi-class physical field finite element simulation data in the component physical model library 103; and the test database stores the data results of the independent tests of the components, and performs classified storage and management.
In some embodiments, the product information display module 101 further includes an instruction issuing sub-module; the instruction issuing sub-module issues simulation run instructions to the system performance model library 102.
In some embodiments, the model real-time submodule discretizes the system performance model according to the real control period of the physical prototype, so as to ensure that the system performance model and the physical prototype run in the same time scale.
In some embodiments, the performance data transceiver submodule is configured to receive simulation instructions and physical prototype sensor data transmitted by the product information display module 101, to receive sensor measurement point information of a system performance test, and to receive model simulation data in the component physical model library 103.
In some embodiments, the multi-field simulation submodule includes a multi-class multi-field simulation environment including: flow field simulation, thermodynamic simulation, intensity simulation and electromagnetic field simulation.
In some embodiments, the performance data transceiver submodule is configured to receive simulation instructions and physical prototype sensor data transmitted by the product information display module 101, receive sensor measurement point information of a system performance test, and receive model simulation data in the component physical model library 103, and send the simulation data to the product information display module 101 and the component physical model library 103 for use.
In some embodiments, the multi-field simulation data transceiving submodule is configured to receive simulation data of the system performance model library 102, and simultaneously send various types of physical field simulation results to the system performance model library 102 and the database 105.
In some embodiments, the physical field data transceiver sub-module is configured to receive simulation and test data in the database 105, receive physical prototype sensing information sent by the product information display module 101, and send virtual sensing results to the product information display module 101.
In some embodiments, the information of the simulation database is obtained by multi-class physical field finite element simulation in the component physical model library 103, and the test database is used for collecting data results of independent tests of the components, and storing and managing the data in a classified manner. The same-category simulation data and test data are packaged and sent to the digital prototype dimension reduction module 104 for data screening and model order reduction.
Based on the same disclosure concept, the invention also discloses a virtual sensing method, which comprises the following steps:
s1: establishing a product information display module, and developing functions of a command issuing sub-module, a data receiving and transmitting sub-module and a product information display sub-module;
s2: introducing a system performance model into a system performance model library, and performing simulation calculation and real-time processing;
s3: introducing a product multi-class physical field finite element model into a component physical model library for simulation calculation;
s4: storing and calling the data in a database;
s5: in a dimension reduction module of the digital prototype, reducing the multiple types of physical field simulation models into a data model which can be synchronously solved with a system performance model;
s6: the physical prototype sends the running state information and the sensor information to the product information display module;
s7: the product information display module sends the state information to the system performance model library, and the system performance model library calculates the full state information of the physical prototype based on the state information and transmits the full state information of the physical prototype back to the product information display module;
s8: the product information display module sends the full-state information of the physical model machine to the dimension reduction module of the digital model machine for further calculation to obtain the physical field information of the core component, and returns the physical field information of the core component to the product information display module;
s9: in the product information display module, the full-state information of the physical prototype and the physical field information of the core component are displayed in a centralized way, and when the acquired information exceeds the normal operation threshold value of the product, an alarm instruction is sent and fault data are reported;
s10: and in the product information display module, comparing and displaying the sensor information with the full-state information of the physical prototype, setting a difference threshold, and when the difference threshold is exceeded, prompting that the accuracy of the virtual sensing system is insufficient, and carrying out factory return updating.
In some embodiments, step S1 comprises: s11: a development instruction issuing sub-module establishes a transmission interface for sending data and receiving data; s12: the method comprises the steps of linking an instruction issuing interface of a product information display module into a system performance model library, wherein the instruction is a start-stop instruction of a digital prototype; s13: respectively linking a data transmission interface of the product information display module to a system performance model library and a dimension reduction module of the digital sample machine; the system performance model library is used for storing the data interface types of the system performance model library, wherein the data interface types linked to the system performance model library are initial conditions and boundary conditions of simulation, and the data interface types linked to the digital prototype dimension reduction module are state information and sensor information of a physical prototype; s14: respectively linking the data receiving interfaces of the product information display module to a physical prototype, a system performance model library and a digital prototype dimension reduction module; the system comprises a physical model machine, a system performance model library, a physical model machine dimension reduction module, a system performance model library, a physical model machine dimension reduction module and a physical model machine dimension reduction module, wherein the type of a data interface connected to the physical model machine is a digital quantity interface capable of receiving real-time acquisition data, the type of a data interface connected to the system performance model library is a full-state real-time simulation result, and the type of a data interface connected to the physical model machine dimension reduction module is a component physical field real-time simulation result; s15: according to the display requirement of the product information display module of the digital prototype system, developing data processing functions such as data processing, cloud drawing, state display, trend analysis and the like corresponding to the data types of the data receiving and transmitting submodule, and loading and displaying the geometric form and the running state of the product in the product information display module.
In some embodiments, step S2 comprises: s21: importing a system performance model supporting Matlab/Simulink and Amesim simulation environments into a system performance model library; s22: carrying out real-time processing on the system performance model, setting corresponding simulation step length according to the control requirement of a physical prototype by adopting fixed-step iterative computation by a solver, and ensuring that the convergence degree of fixed-step simulation and original variable-step simulation is consistent; s23: and carrying out two-round iterative updating on the one-dimensional performance model in the system performance model library, firstly receiving simulation data of the component physical model library, updating a simplified part in the performance model by utilizing the detailed simulation result, then receiving system performance test data, and carrying out proportional correction and iteration on the performance model according to the test data.
In some embodiments, step S3 comprises: s31: leading a finite element physical model supporting Fluent, CFX, mechanical and the like under ANSYS into a component physical model library to perform corresponding simulation calculation; s32: and uploading the simulation result of the component physical model library to a system performance model library through a data interface for iterating the model, and transmitting the simulation result obtained by the component physical model to a basic database for storage through a data transmission interface after classification.
In some embodiments, step S4 comprises: s41: the database 105 receives simulation data of the component physical model library 103 and test data samples of the component independent test and stores the simulation data and the test data samples in a classified manner respectively; s42: the database 105 directs the data to be sent to the digital prototype dimension reduction module for dimension reduction processing of the component physical model.
In some embodiments, step S5 comprises: s51: invoking simulation data of multiple physical field models in a database; s52: establishing a data screening criterion, establishing evaluation indexes from four dimensions of model precision, model robustness, noise influence and calculation cost, and screening and cleaning simulation data samples in a database by adopting an optimal Latin hypercube algorithm function by utilizing a DOE test design method; s53: training simulation data samples screened by a DOE method by adopting a multi-layer neural network algorithm, obtaining a mapping relation between input characteristics and key performances of a multi-field model, and solidifying the trained neural network node parameters; s54: the test data in the database is called to carry out iterative correction on the established mapping relation, wherein a certain proportion of samples are selected as updating samples, and a certain proportion of samples are taken as verification samples so as to ensure the generalization degree of the mapping relation; s55: obtaining an optimal reduced-order data model under an error root mean square and model multidimensional evaluation system; s56: and solidifying the established optimal reduced-order data model in a dimension reduction module of the digital prototype.
Example 1
The present invention also provides an illustrative example, which may include the following: in order to realize the digital delivery of an aircraft electromechanical system-auxiliary power device and improve the full-state monitoring and data accumulation capacity required by the condition-based maintenance, the invention provides a digital prototype system and a virtual sensing method, which can comprise the following steps:
s1: based on the Unity platform, an auxiliary power device digital prototype information display module is developed.
In this embodiment, the Unity is used as a development environment for the digital prototype system of the auxiliary power device to develop the information display interface.
In this embodiment, the Unity development instruction issuing sub-module is used for inputting the execution instruction. The execution instruction performs selection operation in a menu form, including start-stop selection of the digital prototype.
In this embodiment, the Unity is utilized to develop a data transceiver sub-module, wherein a transmission interface between the data collected by the physical prototype sensor and the system model library is interacted with each other in a TCP/IP communication mode, so as to ensure the real-time performance of data transmission, and the data transmission and return are directly performed with the digital prototype dimension reduction module 104 in a FMU encapsulation mode.
In this embodiment, the geometric model of the auxiliary power device established in UG is imported into the Unity platform through the interface file, so as to display the physical structure of the auxiliary power device.
In this embodiment, according to the display requirement, the data display function is developed by using Unity, which includes displaying the operation modes of the auxiliary power device in each operation mode, displaying the pressure, temperature and flow of the full flow path node of the auxiliary power device, displaying the flow field, temperature field and pressure field of the compressor, combustion chamber and turbine, displaying the comparison display and super-threshold alarm display of the real collected data of the key nodes of the flow path and the physical prototype.
S2: and importing the auxiliary power device system performance model into a system performance model library, and carrying out real-time model and simulation calculation.
In the embodiment, an auxiliary power device dynamic transient model established under a Matlab/Simulink platform is imported into a system performance model library.
In the embodiment, an NI platform Veristand function is utilized to convert a dynamic transient model of the auxiliary power device into a real-time model capable of supporting real-time operation and downloading the real-time model into an NI simulator, and an initial condition and a boundary constraint interface are reserved in an upper computer, wherein the initial condition and boundary constraint interface specifically comprise a functional mode, a flight altitude, an environmental temperature and electric load power. And the NI simulator packages and transmits the temperature, pressure and flow information of the inlet and outlet of the gas compressor, the combustion chamber and the power turbine, the electric fuel oil pressure and flow information to the auxiliary power device digital prototype information display module for display in a TCP/IP communication mode.
In this embodiment, the model is real-time to ensure that the flow path simulation results of the original model and the real-time model are not less than 95%.
In this embodiment, the real-time simulation model of the NI platform is to upload the data of the lower computer to the upper computer at the same time, and then send the key information to the component physical model library, which specifically includes: inlet air temperature, pressure and flow information of the compressor, the combustion chamber and the power turbine, and inlet oil flow information of the combustion chamber. The component physical model library uploads the simulation result back to the system performance model library for updating the model, and mainly comprises the following steps: compressor operating pressure ratio/flow characteristics and efficiency/flow characteristics, power turbine expansion ratio/flow characteristics and efficiency/flow characteristics, combustor combustion efficiency and total pressure recovery coefficient.
In this embodiment, the system performance test result is uploaded to the system performance model library through a TCP/IP communication form to perform system performance model correction, and according to the collected flow path information and the simulation flow path information, the model is subjected to second-round correction by changing the pressure loss of the pipeline between the core components, correcting the characteristic relationship of the core components and increasing the scaling factor k.
S3: and introducing multiple types of physical field models into the component physical model library to perform finite element simulation calculation and data collection.
In the embodiment, a finite element model for the performance analysis of a combustion chamber established under a Fluent platform, a compressor established under a CFX/Mechanical platform, a finite element model for the performance analysis of a turbine and a numerical calculation model for the analysis of rotor dynamics established under a Matlab/Simulink platform are respectively imported into a component physical model library, and simulation calculation is performed according to input initial conditions issued by a system performance model library.
In this embodiment, the specific simulation result is uploaded to the system model library for model update.
In this embodiment, simulation data calculated by each platform in the component physical model library is transmitted to the database for storage through data communication.
S4: and storing calculation results and test data of various basic model simulations in a database.
In this embodiment, the transmission data is classified and managed by MySQL.
In this embodiment, the independent test results of the database support component are imported directly through the external interface.
In this embodiment, the simulation data of the component physical model library is directly imported into the simulation database of MySQL through the data interface and stored. The data in the database is sent to the dimension reduction module of the digital prototype through the data interface for use.
S5: in the dimension reduction module of the digital prototype, the finite element model of the component physical model library is subjected to order reduction processing in a data training mode, so that the requirement of real-time model calling is met.
In the embodiment, multi-field model finite element simulation data in a basic database is called, wherein the multi-field model finite element simulation data comprises compressor flow field and structural stress simulation data, combustion chamber flow field and temperature field simulation data and turbine flow field and structural field simulation data, and an optimal Latin hypercube algorithm function is called by utilizing a test design DOE method to screen working conditions and data of finite element simulation.
In this embodiment, before model reduction is performed, performance criteria are established for model reduction, and an index system is established for the auxiliary power device from four dimensions of model accuracy, model robustness, noise influence and calculation time cost.
In the embodiment, a polynomial response surface algorithm, a radial basis function algorithm, a Kriging method or a support vector regression algorithm and other model order reduction algorithms are called in a digital prototype real-time module according to requirements to learn and train the simulation data of the multi-physical-field finite element model.
In this embodiment, independent test data of the compressor, the combustion chamber and the power turbine are called, 70% of sample data is selected to correct and train the training model, and 30% of sample data is selected to verify, so that accuracy and generalization degree of the mapping relation are ensured.
In this embodiment, the dimension reduction module of the digital prototype receives the information of the auxiliary power device information display module to perform quick simulation, and uploads the physical field information of the air compressor, the combustion chamber and the turbine to the auxiliary power device information display module to perform display.
After the developed auxiliary power device digital prototype is delivered, the working flow is as follows:
the auxiliary power device information display module instructs the issuing submodule menu to select the running state, and at the moment, the running state information is sent to the system performance model library, wherein the real-time model is resolved and then the full state information is returned to the auxiliary power device information display module in real time for display.
The characteristic information acquired by the key position sensors of the physical sample is sent to the dimension reduction module of the digital prototype through the auxiliary power device information display module, wherein the dimension reduction module is used for resolving information of flow fields, pressure fields and temperature fields of the compressor, the combustion chamber and the power turbine in real time, and the information is returned to the auxiliary power device information display module for display in real time.
And comparing the characteristic information acquired by the key part sensor of the physical prototype with the information returned by the system performance model library in an auxiliary power device information display module, prompting the digital prototype to deviate from the physical prototype when the error threshold exceeds 5%, and in the subsequent maintenance and guarantee, carrying out maintenance and update on the model and analyzing the characteristic information of the performance decline of the physical prototype according to the result.
It is understood that the term "plurality" in this disclosure means two or more, and other adjectives are similar thereto. "and/or", describes an association relationship of an association object, and indicates that there may be three relationships, for example, a and/or B, and may indicate: a exists alone, A and B exist together, and B exists alone. The character "/" generally indicates that the context-dependent object is an "or" relationship. The singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.
It is further understood that the terms "first," "second," and the like are used to describe various information, but such information should not be limited to these terms. These terms are only used to distinguish one type of information from another and do not denote a particular order or importance. Indeed, the expressions "first", "second", etc. may be used entirely interchangeably. For example, first information may also be referred to as second information, and similarly, second information may also be referred to as first information, without departing from the scope of the present disclosure.
It will be further understood that the terms "center," "longitudinal," "transverse," "front," "rear," "upper," "lower," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like, as used herein, refer to an orientation or positional relationship based on that shown in the drawings, merely for convenience in describing the present embodiments and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operate in a particular orientation.
It will be further understood that "connected" includes both direct connection where no other member is present and indirect connection where other element is present, unless specifically stated otherwise.
It will be further understood that although operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous.
Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure disclosed herein. This disclosure is intended to cover any adaptations, uses, or adaptations of the disclosure following the general principles of the disclosure and including such departures from the present disclosure as come within known or customary practice within the art to which the disclosure pertains. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.
It is to be understood that the present disclosure is not limited to the precise arrangements and instrumentalities shown in the drawings, and that various modifications and changes may be effected without departing from the scope thereof. The scope of the present disclosure is limited only by the appended claims.
Claims (9)
1. A digital prototype, the digital prototype comprising: the system comprises a product information display module, a system performance model library, a component physical model library, a digital prototype dimension reduction module, a database, a physical prototype interface and a ground test system interface;
the product information display module comprises a simulation/operation data receiving and transmitting sub-module and a data display sub-module; the simulation/operation data receiving and transmitting submodule receives real-time simulation information transmitted by the system performance model library, receives part physical field information transmitted by the digital prototype dimension reduction module, and receives state information and sensor information transmitted by a physical prototype, and meanwhile, the simulation/operation data receiving and transmitting submodule transmits initial conditions and boundary constraints to the system performance model library and transmits the state information and the sensor information to the digital prototype dimension reduction module; the data display submodule is used for loading and displaying the geometric form and the running state of the product;
the system performance model library comprises a performance simulation sub-module, a model real-time sub-module and a performance data receiving and transmitting sub-module; the performance simulation submodule is used for carrying out product functional performance simulation and debugging and updating a system performance model; the model real-time submodule is used for carrying out real-time processing on the system performance model;
the component physical model library comprises a multi-field simulation sub-module and a multi-field simulation data receiving and transmitting sub-module; the multi-field simulation sub-module is used for performing simulation calculation on various physical fields of the product component;
the dimension reduction module of the digital prototype comprises a test data screening sub-module, a dimension reduction algorithm sub-module and a physical field data receiving and transmitting sub-module; the test data screening submodule is used for screening mass data of the database; the dimension reduction algorithm submodule is used for carrying out dimension reduction treatment on multiple types of physical field models in the component physical model library;
the ground test system comprises a system performance test and a component independent test;
the database comprises a simulation database and a test database; the simulation database stores multi-class physical field finite element simulation data in the component physical model library; and the test database stores data results of independent tests of the storage component for classified storage and management.
2. The digital prototype of claim 1, wherein said product information display module further comprises an instruction issuing sub-module; and the instruction issuing sub-module issues a simulation operation instruction to the system performance model library.
3. The digital prototype of claim 1, wherein the model real-time sub-module discretizes the system performance model according to a real control period of the physical prototype to ensure that the system performance model and the physical prototype operate on the same time scale.
4. The digital prototype of claim 1, wherein the performance data transceiver sub-module is configured to receive simulation instructions and physical prototype sensor data transmitted by the product information display module, receive sensor measurement point information of the system performance test, and receive model simulation data in the component physical model library.
5. The digital prototype as claimed in claim 1, wherein said multi-field simulation sub-module comprises a multi-class multi-field simulation environment, said multi-class multi-field simulation environment comprising: flow field simulation, thermodynamic simulation, intensity simulation and electromagnetic field simulation.
6. A virtual sensing method of a digital prototype according to any one of claims 1-5, comprising the steps of:
s1: establishing a product information display module, and developing functions of a command issuing sub-module, a data receiving and transmitting sub-module and a product information display sub-module;
s2: introducing a system performance model into a system performance model library, and performing simulation calculation and real-time processing;
s3: introducing a product multi-class physical field finite element model into a component physical model library for simulation calculation;
s4: storing and calling the data in a database;
s5: in a dimension reduction module of the digital prototype, reducing the multiple types of physical field simulation models into a data model which can be synchronously solved with a system performance model;
the step S5 includes:
s51: invoking simulation data of multiple physical field models in a database;
s52: establishing a data screening criterion, establishing evaluation indexes from four dimensions of model precision, model robustness, noise influence and calculation cost, and screening and cleaning simulation data samples in a database by adopting an optimal Latin hypercube algorithm function by utilizing a DOE test design method;
s53: training simulation data samples screened by a DOE method by adopting a multi-layer neural network algorithm, obtaining a mapping relation between input characteristics and key performances of a multi-field model, and solidifying the trained neural network node parameters;
s54: the test data in the database is called to carry out iterative correction on the established mapping relation, wherein part of samples are selected as updating samples, and part of samples are used as verification samples so as to ensure the generalization degree of the mapping relation;
s55: obtaining an optimal reduced-order data model under an error root mean square and model multidimensional evaluation system;
s56: solidifying the established optimal reduced-order data model in a dimension reduction module of the digital prototype;
s6: the physical prototype sends the running state information and the sensor information to the product information display module;
s7: the product information display module sends the state information to the system performance model library, and the system performance model library calculates the full state information of the physical prototype based on the state information and transmits the full state information of the physical prototype back to the product information display module;
s8: the product information display module sends the full-state information of the physical model machine to the dimension reduction module of the digital model machine for further calculation to obtain the physical field information of the core component, and returns the physical field information of the core component to the product information display module;
s9: in the product information display module, the full-state information of the physical prototype and the physical field information of the core component are displayed in a centralized way, and when the acquired information exceeds the normal operation threshold value of the product, an alarm instruction is sent and fault data are reported;
s10: and in the product information display module, comparing and displaying the sensor information with the full-state information of the physical prototype, setting a difference threshold, and when the difference threshold is exceeded, prompting that the accuracy of the virtual sensing system is insufficient, and carrying out factory return updating.
7. The virtual sensing method according to claim 6, wherein the step S1 comprises:
s11: a development instruction issuing sub-module establishes a transmission interface for sending data and receiving data;
s12: the method comprises the steps of linking an instruction issuing interface of a product information display module into a system performance model library, wherein the instruction is a start-stop instruction of a digital prototype;
s13: respectively linking a data transmission interface of the product information display module to a system performance model library and a dimension reduction module of the digital sample machine; the system performance model library is used for storing the data interface types of the system performance model library, wherein the data interface types linked to the system performance model library are initial conditions and boundary conditions of simulation, and the data interface types linked to the digital prototype dimension reduction module are state information and sensor information of a physical prototype;
s14: respectively linking the data receiving interfaces of the product information display module to a physical prototype, a system performance model library and a digital prototype dimension reduction module; the system comprises a physical model machine, a system performance model library, a physical model machine dimension reduction module, a system performance model library, a physical model machine dimension reduction module and a physical model machine dimension reduction module, wherein the type of a data interface connected to the physical model machine is a digital quantity interface capable of receiving real-time acquisition data, the type of a data interface connected to the system performance model library is a full-state real-time simulation result, and the type of a data interface connected to the physical model machine dimension reduction module is a component physical field real-time simulation result;
s15: according to the display requirement of the product information display module of the digital prototype system, developing data processing, cloud drawing, state display and trend analysis data processing functions corresponding to the data types of the data receiving and transmitting submodules, and loading and displaying the geometric form and the running state of the product in the product information display module.
8. The virtual sensing method according to claim 6, wherein the step S2 comprises:
s21: importing a system performance model supporting Matlab/Simulink and Amesim simulation environments into a system performance model library;
s22: carrying out real-time processing on the system performance model, setting corresponding simulation step length according to the control requirement of a physical prototype by adopting fixed-step iterative computation by a solver, and ensuring that the convergence degree of fixed-step simulation and original variable-step simulation is consistent;
s23: and carrying out two-round iterative updating on the one-dimensional performance model in the system performance model library, firstly receiving simulation data of the component physical model library, updating a simplified part in the performance model by utilizing the detailed simulation result, then receiving system performance test data, and carrying out proportional correction and iteration on the performance model according to the test data.
9. The virtual sensing method according to claim 6, wherein the step S3 comprises:
s31: leading a Fluent, CFX, mechanical finite element physical model supporting ANSYS into a component physical model library to perform corresponding simulation calculation;
s32: and uploading the simulation result of the component physical model library to a system performance model library through a data interface for iterating the model, and transmitting the simulation result obtained by the component physical model to a basic database for storage through a data transmission interface after classification.
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