CN108692946B - Water-cooling and intermediate-cooling device for engine bench test and control method thereof - Google Patents
Water-cooling and intermediate-cooling device for engine bench test and control method thereof Download PDFInfo
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- CN108692946B CN108692946B CN201810484158.9A CN201810484158A CN108692946B CN 108692946 B CN108692946 B CN 108692946B CN 201810484158 A CN201810484158 A CN 201810484158A CN 108692946 B CN108692946 B CN 108692946B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M15/00—Testing of engines
- G01M15/02—Details or accessories of testing apparatus
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D23/00—Control of temperature
- G05D23/19—Control of temperature characterised by the use of electric means
- G05D23/1927—Control of temperature characterised by the use of electric means using a plurality of sensors
- G05D23/1928—Control of temperature characterised by the use of electric means using a plurality of sensors sensing the temperature of one space
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Abstract
The invention discloses a water-cooling and intermediate-cooling device for an engine bench test and a control method thereof, wherein the device comprises a main controller, a sub-controller, an electronic water pump, an intercooler, a plate heat exchanger, a liquid supplementing kettle, an electromagnetic water valve, a first temperature sensor, a second temperature sensor and a third temperature sensor, wherein the first temperature sensor detects the temperature of a cooling liquid before the intercooler, the second temperature sensor detects the temperature of air outlet after the intercooler, and the third temperature sensor detects the temperature of air inlet before the intercooler; the main controller utilizes the temperature of the cooling liquid before the intercooling, the temperature of the air discharged after the intercooling and the temperature of the air inlet before the intercooling to perform cascade control on the rotating speed of the adjusting electronic water pump and the opening of the adjusting electromagnetic water valve after a fuzzy PID algorithm and a Smith estimation algorithm, so that the quick, accurate and stable control on the temperature of the air inlet after the intercooling and the temperature of the cooling liquid before the intercooling is realized.
Description
Technical Field
The invention belongs to the field of automobile engine testing, and particularly relates to a water-cooling and intermediate-cooling device for an engine bench test and a control method thereof.
Background
research shows that the engine power can be improved by 3-5% when the inlet air temperature is reduced by 10 ℃, and the detonation rate of the engine can be reduced. Particularly, in a turbocharged engine, the temperature of air after turbocharging can reach 150 ℃ or even higher, and the accurate control of the air inlet temperature after middle cooling and air outlet cooling is very important.
At present, an intercooler system adopted on a whole vehicle mainly has an external air cooling type and an integrated water cooling type. The external air-cooling type is to cool the pressurized air by using the atmosphere. The integrated water-cooled intercooler system comprises a high-temperature heat exchanger and a low-temperature radiator, wherein the high-temperature heat exchanger is integrated on an engine body, the supercharged air is cooled by cooling liquid, the flow of the cooling liquid is controlled by a circulating water pump (namely an electronic water pump), and the low-temperature radiator is arranged at the front end of a vehicle head and utilizes the atmosphere to take away the heat of the cooling liquid. The original air cooling is replaced by water cooling on an engine pedestal, and the control of the inlet air temperature of the supercharged engine is finally realized by adjusting the flow of a cooling medium entering a heat exchanger.
for an integrated water-cooled engine, an open-loop control mode is usually adopted on the whole vehicle, and the rotating speed of a circulating water pump is calculated according to the rotating speed, the torque, the opening degree of a throttle valve and the like of the engine to perform real-time regulation. The closed loop single loop control of the intake air temperature after intercooling is usually adopted on the engine pedestal, and a PID controller is usually adopted as the controller. The PID control is the controller which is most widely applied in industry, the PID controller is simple and easy to use, a system model of a controlled object is not needed when the PID controller is used, but the PID controller is generally only suitable for a system which is simple and linear, has small time delay, is not time-varying or has small dynamic characteristic change, when a nonlinear element exists in the system, a self-excited oscillation phenomenon may occur, and when the working condition or the state of an engine is found to change, the stability and the performance of the system can also change.
CN106968777A discloses an engine intercooler device and a control method thereof, which can control the intake air temperature after supercharging by an engine intercooler, but when the working condition or the required temperature of the engine changes, the intake air temperature of the engine (i.e. the exhaust air temperature after intercooler) and the temperature of the coolant before intercooler can not quickly, accurately and stably reach the set temperature, and the requirements of the current six developments in China on the accuracy, range and stability of the intake air temperature of the engine can not be met.
Disclosure of Invention
The invention aims to provide a water-cooling and intermediate-cooling device for an engine bench test and a control method thereof, so as to realize quick, accurate and stable control of the outlet air temperature after intermediate cooling and the coolant temperature before intermediate cooling.
The invention relates to a water cooling and inter-cooling device for an engine bench test, which comprises a sub-controller, an electronic water pump, an inter-cooler, a plate heat exchanger and a liquid supplementing kettle, a cooling liquid outlet of the plate heat exchanger is connected with a cooling liquid inlet of the intercooler through a liquid supplementing kettle and an electronic water pump, the cooling liquid outlet of the intercooler is connected with the cooling liquid inlet of the plate heat exchanger, the liquid supplementing kettle, the electronic water pump and the intercooler form a cooling liquid circulation loop, a first temperature sensor for detecting the temperature of cooling liquid before intercooling (namely the temperature of the cooling liquid flowing into the intercooler) is arranged in a pipeline between the electronic water pump and the intercooler, a second temperature sensor for detecting the temperature of air outlet after intercooling (namely the temperature of the air outlet of the intercooler) is arranged in a pipeline between the intercooler and the engine, and the electronic water pump, the first temperature sensor and the second temperature sensor are all electrically connected with a; the water-cooling intercooler device further comprises an electromagnetic water valve, a third temperature sensor and a main controller, wherein the electromagnetic water valve is installed on a cooling water inlet pipe of the plate heat exchanger and used for adjusting the flow of cooling water flowing into the plate heat exchanger, the third temperature sensor is installed in a pipeline between the intercooler and the supercharger and used for detecting the air inlet temperature before intercooler (namely the air inlet temperature of the intercooler), the electromagnetic water valve, the third temperature sensor and the main controller are electrically connected with a sub-controller, the first temperature sensor, the second temperature sensor and the third temperature sensor are used for sending detected temperature data (namely the temperature of the cooling water before intercooler, the air outlet temperature after intercooler and the air inlet temperature before intercooler) to the sub-controller, the sub-controller sends the temperature data to the main controller, and the rotating speed of the electronic water pump and the opening degree of the electromagnetic water valve are.
The first temperature sensor, the second temperature sensor and the third temperature sensor are respectively connected with an analog signal acquisition port of the sub-controller through a temperature transmitter.
the main controller is a virtual instrument developed based on LabVIEW and is electrically connected with the sub-controllers through serial ports.
The invention relates to a water-cooling intercooling control method for an engine pedestal test, which adopts the water-cooling intercooling device and comprises the following steps:
A. The main controller sets the set value T of the outlet air temperature after inter-coolingout _ gas _ svand the actual value T of the after-intercooling outlet air temperature detected by the second temperature sensorout _ gasSubtracting to obtain the outlet air temperature deviation delta T after inter-coolingout _ gas(ii) a Subtracting the air outlet temperature deviation after the current intercooling from the air outlet temperature deviation after the last intercooling, and dividing the difference by time to obtain the air outlet temperature deviation change rate delta e after the intercoolingout _ gas。
B. The main controller utilizes the after-intercooling air outlet temperature deviation delta T obtained in the step Aout _ gasAnd the rate of change delta e of the deviation of the outlet air temperature after intercoolingout _ gasAnd obtaining the duty ratio of the PWM signal required by the control of the electronic water pump after the fuzzy PID algorithm and the Smith estimation algorithm.
C. And D, the main controller sends the duty ratio obtained in the step B to a sub-controller, and the sub-controller generates a corresponding PWM signal to adjust the rotating speed of the electronic water pump.
D. The main controller sets the temperature T of the pre-intercooling cooling liquidin _ liquid _ svAnd the actual value T of the pre-intercooling cooling liquid temperature detected by the first temperature sensorin _ liquidSubtracting to obtain the temperature deviation delta T of the pre-intercooling cooling liquidin _ liquid(ii) a Subtracting the current before-intercooling coolant temperature deviation from the last before-intercooling coolant temperature deviation, and dividing by time to obtain the before-intercooling coolant temperature deviation change rate delta ein _ liquid。
E. D, the main controller utilizes the temperature deviation delta T of the pre-intercooling cooling liquid obtained in the step Din _ liquidand rate of change of coolant temperature deviation Δ e before inter-coolingin _ liquidAnd obtaining control output corresponding to the opening degree of the electromagnetic water valve after the fuzzy PID algorithm and the Smith estimation algorithm.
F. And E, sending the control output obtained in the step E to a sub-controller, and generating a corresponding analog signal by the sub-controller to adjust the opening of the electromagnetic water valve.
G. Repeating the steps A to F, and obtaining the actual value T of the outlet air temperature after intercoolingout _ gasWill gradually approach the set value T of the outlet air temperature after intercoolingout _ gas _ svActual value of intercooling pre-coolant temperature Tin _ liquidWill gradually approach the pre-intercooling coolant temperature setpoint Tin _ liquid _ svAnd tends to be stable.
Wherein, the inter-cold pre-cooling liquid temperature set value Tin _ liquid _ svThis can be achieved in two ways: the first way is through calculation, namely the main controller uses the duty ratio obtained in the step B and the actual value T of the middle cooling forward air temperature detected by the third temperature sensorin _ qiObtaining the set value T of the pre-intercooling coolant temperature after a fuzzy control algorithmin _ liquid _ sv(ii) a Second, the pre-chilled coolant temperature setpoint T is set manually, i.e., manually on the main controllerin _ liquid _ sv。
The invention can make the after-intercooling outlet air temperature and the before-intercooling coolant temperature quickly, accurately and stably reach the set temperature when the working condition or the required temperature of the engine changes, realize the quick, accurate and stable control of the after-intercooling outlet air temperature and the before-intercooling coolant temperature, ensure that the test process is under the same boundary condition, and ensure the normal development of special tests.
Drawings
Fig. 1 is a schematic structural diagram of a water-cooling intercooler device in the present invention.
Fig. 2 is a schematic block diagram of the water cooling intercooling control in the present invention.
Detailed Description
The present invention will be described in detail with reference to the accompanying drawings.
The water-cooling and intermediate-cooling device for the engine bench test shown in fig. 1 comprises a main controller 1, a sub-controller 2, an electronic water pump 3, an electromagnetic water valve 4, an intermediate cooler 9, a plate heat exchanger 10, a liquid supplementing kettle 11, a first temperature sensor 5, a second temperature sensor 15 and a third temperature sensor 14, wherein the first temperature sensor 5, the second temperature sensor 15 and the third temperature sensor 14 are all PT100, a cooling liquid outlet of the plate heat exchanger 10 is connected with a cooling liquid inlet of the intermediate cooler 9 through the liquid supplementing kettle 11 and the electronic water pump 3, a cooling liquid outlet of the intermediate cooler 9 is connected with the cooling liquid inlet of the plate heat exchanger 10, the liquid supplementing kettle 11, the electronic water pump 3 and the intermediate cooler 9 form a cooling liquid circulation loop, the electromagnetic water valve 4 is arranged on a cooling water inlet pipe 12 of the plate heat exchanger 10 to regulate the flow rate of cooling water flowing into the plate heat, the cooling water outlet pipe 13 of the plate heat exchanger 10 may communicate with a subsequent radiator. The sub-controller 2 is an STM8 single chip microcomputer system, the motor of the electronic water pump 3 is a direct current brushless motor, the main controller 1 is a virtual instrument developed based on LabVIEW, and an engineer can set an intercooling rear outlet air temperature set value T on the main controller 1out _ gas _ svAnd a pre-intercooling coolant temperature setpoint Tin _ liquid _ sv。
A first temperature sensor 5 is installed in the pipeline between the electronic water pump 3 and the intercooler 9 and used for detecting the temperature of the pre-intercooling coolant (i.e. the temperature of the coolant flowing into the intercooler 9), the first temperature sensor 5 is connected with an analog signal acquisition port of the sub-controller 2 through a temperature transmitter 6, and the detected temperature of the pre-intercooling coolant (i.e. the actual value T of the pre-intercooling coolant) is detectedin _ liquid) To the sub-controller 2. A second temperature sensor 15 is installed in the pipeline between the intercooler 9 and the engine 7 and used for detecting the after-intercooling outlet air temperature (namely the outlet air temperature of the intercooler 9), the second temperature sensor 15 is connected with another analog signal acquisition port of the sub-controller 2 through another temperature transmitter 6, and the detected after-intercooling outlet air temperature (namely the actual value T of the after-intercooling outlet air temperature) is detectedout _ gas) To the sub-controller 2. A third temperature sensor 14 is installed in the pipeline between the intercooler 9 and the supercharger 8 and used for detecting the before-intercooling inlet air temperature (namely the inlet air temperature of the intercooler 9), a second temperature sensor 15 is connected with a third analog signal acquisition port of the sub-controller 2 through a third temperature transmitter 6 and used for detecting the before-intercooling inlet air temperature (namely the actual value T of the before-intercooling inlet air temperature)in _ qi) To the sub-controller 2.
The sub-controller 2 is electrically connected with the main controller 1 through a serial port and used for measuring the actual temperature T of the pre-intercooling cooling liquidin _ liquidActual value T of outlet air temperature after intercoolingout _ gasActual value T of intercooling forward air temperaturein _ qiThe control command of the electronic water pump and the electromagnetic water valve is sent to the main controller 1 for calculation and processing, the main controller 1 sends the control command of the electronic water pump and the electromagnetic water valve to the sub-controller 2 after calculation and processing, the sub-controller 2 adjusts the rotating speed of the electronic water pump 3 according to the control command of the electronic water pump, and adjusts the opening degree of the electromagnetic water valve 4 according to the control command of the electromagnetic water valve.
The water-cooling intercooling control method for the engine bench test shown in fig. 2, which adopts the water-cooling intercooling device, comprises:
Firstly, the main controller 1 sets the outlet air temperature set value T after intercoolingout _ gas _ svAnd the actual value T of the after-intercooling outlet air temperature detected by the second temperature sensor 15out _ gasAre subtracted to obtainAfter intercooling, the temperature deviation Delta T of outlet airout _ gas(ii) a Subtracting the air outlet temperature deviation after the current intercooling from the air outlet temperature deviation after the last intercooling, and dividing the difference by time to obtain the air outlet temperature deviation change rate delta e after the intercoolingout _ gas。
Secondly, the main controller 1 utilizes the intercooled air outlet temperature deviation delta T obtained in the first stepout _ gasAnd the rate of change delta e of the deviation of the outlet air temperature after intercoolingout _ gasAnd obtaining the duty ratio of the PWM signal required by the control of the electronic water pump after the fuzzy PID algorithm and the Smith estimation algorithm.
And thirdly, the main controller 1 sends the duty ratio obtained in the second step to the sub-controllers 2 through serial ports, and the sub-controllers 2 generate corresponding PWM signals and adjust the rotating speed of the electronic water pump 3.
Fourthly, the main controller 1 judges the current coolant temperature set value mode before the inter-cooling: if the mode is the automatic adjusting mode, the duty ratio obtained in the second step and the actual value T of the middle cooling forward air temperature detected by the third temperature sensor 14 are utilizedin _ qiObtaining a set value T of the pre-intercooling coolant temperature after a fuzzy control algorithmin _ liquid _ sv(ii) a If the mode is manual adjustment mode, the coolant temperature setting T before the intercooler set by the engineer in the main controller 1 is readin _ liquid _ sv。
Fifthly, the main controller 1 sets the temperature of the pre-intercooling coolant to be a set value Tin _ liquid _ svAnd the actual value T of the pre-mid-cooling liquid temperature detected by the first temperature sensor 5in _ liquidSubtracting to obtain the temperature deviation delta T of the pre-intercooling cooling liquidin _ liquid(ii) a Subtracting the current before-intercooling coolant temperature deviation from the last before-intercooling coolant temperature deviation, and dividing by time to obtain the before-intercooling coolant temperature deviation change rate delta ein _ liquid。
Sixthly, the main controller 1 utilizes the temperature deviation Delta T of the pre-intercooling coolant obtained in the fifth stepin _ liquidAnd rate of change of coolant temperature deviation Δ e before inter-coolingin _ liquidAnd obtaining control output corresponding to the opening degree of the electromagnetic water valve after the fuzzy PID algorithm and the Smith estimation algorithm.
And step seven, sending the control output obtained in the step six to the sub-controller 2 through a serial port, wherein the sub-controller 2 generates a corresponding analog signal and adjusts the opening degree of the electromagnetic water valve 4.
Eighthly, repeating the first step to the seventh step, and giving out the actual value T of the air temperature after the intercoolingout _ gasWill gradually approach the set value T of the outlet air temperature after intercoolingout _ gas _ svActual value of intercooling pre-coolant temperature Tin _ liquidWill gradually approach the pre-intercooling coolant temperature setpoint Tin _ liquid _ svAnd tends to be stable.
In the embodiment, fuzzy PID control can realize real-time automatic regulation of PID parameters and dynamic performance improvement according to different engine working conditions and changes of the working conditions, Smith estimation control eliminates time delay of a cooling system, stability of the system is improved, regulation time is shortened, cascade control is adopted for regulating the rotating speed of an electronic water pump and regulating the opening degree of an electromagnetic water valve, dynamic characteristics of the process are improved, system control quality is improved, disturbance caused by changes of inlet air temperature and pressure before intercooling can be quickly overcome, and meanwhile, the control range and the precision of outlet air temperature after intercooling are also improved; therefore, the embodiment realizes the quick, accurate and stable control of the middle-cold rear intake air temperature and the middle-cold front cooling liquid temperature. In addition, the embodiment has the functions of manually adjusting and automatically adjusting the pre-cooling coolant temperature set value, and has better applicability and greater flexibility.
Claims (3)
1. A water-cooling and inter-cooling control method for an engine pedestal test is characterized in that an adopted water-cooling and inter-cooling device comprises a sub-controller (2), an electronic water pump (3), an inter-cooler (9), a plate heat exchanger (10) and a liquid supplementing kettle (11), a cooling liquid outlet of the plate heat exchanger (10) is connected with a cooling liquid inlet of the inter-cooler (9) through the liquid supplementing kettle (11) and the electronic water pump (3), a cooling liquid outlet of the inter-cooler (9) is connected with a cooling liquid inlet of the plate heat exchanger (10), a first temperature sensor (5) for detecting the temperature of cooling liquid before inter-cooling is arranged in a pipeline between the electronic water pump (3) and the inter-cooler (9), a second temperature sensor (15) for detecting the temperature of outlet air after inter-cooling is arranged in a pipeline between the inter-cooler (9) and an engine (7), the electronic water pump (3), the first temperature sensor (5) and, the cooling system is characterized by further comprising an electromagnetic water valve (4), a third temperature sensor (14) and a main controller (1), wherein the electromagnetic water valve (4) is installed on a cooling water inlet pipe (12) of the plate type heat exchanger (10) and used for adjusting the flow of cooling water flowing into the plate type heat exchanger (10), the third temperature sensor (14) is installed in a pipeline between an intercooler (9) and a supercharger (8) and used for detecting the temperature of inlet air before intercooling, the electromagnetic water valve (4), the third temperature sensor (14) and the main controller (1) are electrically connected with the sub-controller (2), the first temperature sensor, the second temperature sensor, the third temperature sensor (5, 15 and 14) send detected temperature data to the sub-controller (2), and the sub-controller (2) sends the temperature data to the main controller (1), the rotating speed of the electronic water pump (3) and the opening degree of the electromagnetic water valve (4) are adjusted according to a control instruction of the main controller (1); the control method is characterized by comprising the following steps:
A. The main controller (1) sets the air outlet temperature T after inter-coolingout _ gas _ svAnd the actual value T of the after-intercooling outlet air temperature detected by the second temperature sensor (15)out _ gasSubtracting to obtain the outlet air temperature deviation delta T after inter-coolingout _ gas(ii) a Subtracting the air outlet temperature deviation after the current intercooling from the air outlet temperature deviation after the last intercooling, and dividing the difference by time to obtain the air outlet temperature deviation change rate delta e after the intercoolingout _ gas；
B. The main controller (1) utilizes the after-intercooling air outlet temperature deviation delta T obtained in the step Aout _ gasAnd the rate of change delta e of the deviation of the outlet air temperature after intercoolingout _ gasObtaining the duty ratio of a PWM signal required by controlling the electronic water pump after the fuzzy PID algorithm and the Smith estimation algorithm;
C. the main controller (1) sends the duty ratio obtained in the step B to the sub-controller (2), and the sub-controller (2) generates a corresponding PWM signal to adjust the rotating speed of the electronic water pump (3);
D. The main controller (1) sets the temperature of the pre-intercooling cooling liquid to be a set value Tin _ liquid _ svAnd the actual value T of the pre-middle cooling liquid temperature detected by the first temperature sensor (5)in _ liquidSubtracting to obtain the temperature deviation delta T of the pre-intercooling cooling liquidin _ liquid(ii) a Subtracting the current before-intercooling coolant temperature deviation from the last before-intercooling coolant temperature deviation, and dividing by time to obtain the before-intercooling coolant temperature deviation change rate delta ein _ liquid(ii) a Wherein the intercooling pre-cooling liquid temperature set value Tin _ liquid _ svFor manually set values on the main controller (1) or for the main controller (1) by using the duty ratio obtained in the step B and the actual value T of the intercooled front intake air temperature detected by the third temperature sensor (14)in _ qiObtaining a numerical value through a fuzzy control algorithm;
E. The main controller (1) utilizes the temperature deviation delta T of the pre-intercooling cooling liquid obtained in the step Din _ liquidAnd rate of change of coolant temperature deviation Δ e before inter-coolingin _ liquidObtaining control output corresponding to the opening degree of the electromagnetic water valve after the fuzzy PID algorithm and the Smith estimation algorithm;
F. Sending the control output obtained in the step E to a sub-controller (2), wherein the sub-controller (2) generates a corresponding analog signal and adjusts the opening of the electromagnetic water valve (4);
G. Repeating the steps A to F, and obtaining the actual value T of the outlet air temperature after intercoolingout _ gasWill gradually approach the set value T of the outlet air temperature after intercoolingout _ gas _ svActual value of intercooling pre-coolant temperature Tin _ liquidWill gradually approach the pre-intercooling coolant temperature setpoint Tin _ liquid _ svAnd tends to be stable.
2. The water-cooling intercooling control method for the engine bench test according to claim 1, characterized in that: the first, second and third temperature sensors (5, 15, 14) are respectively connected with an analog signal acquisition port of the sub-controller (2) through a temperature transmitter (6).
3. The water-cooling intercooling control method for the engine bench test according to claim 1, characterized in that: the main controller (1) is a virtual instrument developed based on LabVIEW, and the main controller (1) is electrically connected with the sub-controller (2) through a serial port.
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| CN110907184A (en) * | 2019-11-28 | 2020-03-24 | 中汽研汽车检验中心(昆明)有限公司 | Method for detecting and controlling outlet temperature of intercooler for engine test |
| CN114198193B (en) * | 2020-09-02 | 2023-02-03 | 上海汽车集团股份有限公司 | Data processing method and device for temperature of cooling liquid of water-air cooling system |
| CN113107660B (en) * | 2021-03-31 | 2022-08-19 | 潍柴重机股份有限公司 | Control method of intercooler cooling system |
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