CN112017499B - Semi-physical loading and unloading machine simulator system based on simulation technology - Google Patents
Semi-physical loading and unloading machine simulator system based on simulation technology Download PDFInfo
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- CN112017499B CN112017499B CN202010692566.0A CN202010692566A CN112017499B CN 112017499 B CN112017499 B CN 112017499B CN 202010692566 A CN202010692566 A CN 202010692566A CN 112017499 B CN112017499 B CN 112017499B
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- G09B9/00—Simulators for teaching or training purposes
Abstract
The invention discloses a semi-physical loading and unloading machine simulator system based on a simulation technology, which comprises a loading and unloading machine console and a loading and unloading machine simulator system; the loading and unloading machine control console is connected with the loading and unloading machine simulator system through a quick-plug connector; the loading and unloading machine simulator system generates simulation signals according to the signal mathematical model of the physical entity equipment. The beneficial effects of the invention are as follows: the semi-physical loading and unloading machine simulator system based on the simulation technology has the advantages of simple design, flexible simulation, small equipment occupation space and low cost. Meanwhile, the system not only can freely select/switch preset parameters of two units and realize the training of the reloading operation of different machine assembly unloading machines, but also can perform performance inspection on electric components in a console of the loading and unloading machine in advance before the beginning of the reloading overhaul of the units, and can replace the electric components with invalid functions in the console in advance so as to ensure the smooth implementation of the reloading overhaul work of the nuclear power station units.
Description
Technical Field
The invention belongs to the field of nuclear power, and particularly relates to a semi-physical loading and unloading machine simulator system based on a simulation technology.
Background
The loading and unloading machine is one of key devices of a fuel operation and storage system of a pressurized water reactor nuclear power plant and is arranged above a refueling water tank of the reactor. During a nuclear power plant shutdown refueling, it is responsible for completing loading and unloading and transfer operations of fuel assemblies between the reactor core and the tipping frame of the fuel transfer device. At present, a nuclear power station adopts a long-period refueling mode, and a unit performs shutdown refueling once every 18 months. After the material changing is finished, the material loading and unloading machine is parked in the reactor factory building, and an operator cannot learn and train the material changing operation process by using the material loading and unloading machine.
At present, the design schemes of a simulator system of a loading and unloading machine of a nuclear power station mainly comprise 3 kinds: according to the technical scheme, the PC computer with a graphic workstation is mainly used for carrying out motion simulation of a large and small vehicle and a gripping apparatus, the 1:1 loading and unloading machine control console is required to be redesigned, the existing loading and unloading machine control console is not fully utilized, the design cost of the whole loading and unloading machine simulator system is increased, and the performance of electrical equipment in the existing loading and unloading machine control console cannot be checked; a simulation model (authority number 201210382048.4) of a loading and unloading machine console is designed, and a loading and unloading operation process simulation system is formed by combining a built-in controller PC workstation and an LED display screen. The other is a simulation system (authority number 201410324108.6) which is specially used for checking the handling capacity of field personnel on handling faults of the loading and unloading machine, and consists of two parts, namely monitoring equipment and a controller, wherein the monitoring equipment is used for generating fault simulation signals and checking the handling condition of the field personnel on the faults; the controller is used for logically processing and outputting fault simulation signals, and the system has single function and can be only used for fault simulation.
In view of this, the present invention has been made.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a semi-physical loading and unloading machine simulator system based on a simulation technology, which can simulate various operation conditions of a loading and unloading machine, realize the training of the loading and unloading operation of a loading and unloading machine operator, and can carry out integral inspection on the performance of an electric component in a loading and unloading machine console in advance before the loading and unloading overhaul of a nuclear power plant unit starts, thereby being convenient for replacing the electric component with invalid function in the console in advance and effectively ensuring the smooth implementation of the loading and unloading overhaul work of the nuclear power plant unit.
The technical scheme of the invention is as follows:
a semi-physical loading and unloading machine simulator system based on simulation technology comprises a loading and unloading machine control board and a loading and unloading machine simulator system; the loading and unloading machine control console is connected with the loading and unloading machine simulator system through a quick-plug connector; the loading and unloading machine simulator system generates simulation signals according to the signal mathematical model of the physical entity equipment.
Further, the above-mentioned semi-physical loading and unloading machine simulator system based on simulation technology, the loading and unloading machine simulator system includes:
the input signal acquisition module is used for receiving analog quantity signals from a control console of the loading and unloading machine and switching value signals from an upper computer;
the simulation signal generation module is used for dynamically generating simulation signals of the physical entity equipment in real time according to the input signals received by the input signal acquisition module;
the simulation signal output module is used for outputting the generated simulation signal to the loading and unloading machine console in real time;
and the upper computer data processing module is used for real-time data processing between the upper computer and the simulation signal generating module.
Further, the above-mentioned semi-physical loading and unloading machine simulator system based on simulation technology, the loading and unloading machine simulator system further includes:
and the parameter setting module is used for presetting on-site operation parameters of the loading and unloading machine.
Furthermore, in the semi-physical loading and unloading machine simulator system based on the simulation technology, the number of on-site operation parameters of the loading and unloading machines is two, and the parameter values are completely consistent with the actual measurement physical parameters of the reactor core where the loading and unloading machines of the two units are located.
Further, the above-mentioned semi-physical loading and unloading machine simulator system based on simulation technology, the loading and unloading machine simulator system further includes:
and the initialization module is used for initializing assignment so as to output a default value to the loading and unloading machine console after the system is electrified, and ensuring that the whole material changing operation training system works in a normal state.
Further, in the above-mentioned semi-physical loading and unloading machine simulator system based on simulation technology, the switching value signal includes: the operator operates the handle, button or upper computer picture on the control console of the loader and the unloader, and sends out running direction command, gripping apparatus control command, encoder power state and interlocking signal between the loader and the fuel transfer device.
Further, in the above-mentioned semi-physical loading and unloading machine simulator system based on simulation technology, the analog quantity signal includes: a speed set signal, an encoder clock signal, and a motor rotary encoder excitation signal.
Further, in the semi-physical loading and unloading machine simulator system based on the simulation technology, the simulation signals comprise switching value output signals and analog value output signals; the switching value output signals comprise analog signals of a hand wheel, a safety limit, an anti-collision limit, a rope breakage limit and a brake band-type brake of the loading and unloading machine and/or a brake abrasion sensor of the loading and unloading machine; the analog output signal includes an encoder gray code, a motor resolver, and an analog signal of a load sensor.
The beneficial effects of the invention are as follows:
the semi-physical loading and unloading machine simulator system based on the simulation technology has the advantages of simple design, flexible simulation, small equipment occupation space and low cost. Meanwhile, the system not only can freely select/switch preset parameters of two units and realize the training of the reloading operation of different machine assembly unloading machines, but also can perform performance inspection on electric components in a console of the loading and unloading machine in advance before the beginning of the reloading overhaul of the units, and can replace the electric components with invalid functions in the console in advance so as to ensure the smooth implementation of the reloading overhaul work of the nuclear power station units.
Drawings
FIG. 1 is a block diagram of a semi-physical loading and unloading machine simulator system based on simulation technology of the invention.
Detailed Description
An embodiment of a method for manufacturing a test piece according to the present invention will be described with reference to the accompanying drawings:
as shown in FIG. 1, the invention provides a semi-physical loading and unloading machine simulator system based on a simulation technology, which comprises a loading and unloading machine console and a loading and unloading machine simulator system; the loading and unloading machine control console is connected with the loading and unloading machine simulator system through a quick-plug connector; the loading and unloading machine simulator system generates simulation signals according to the signal mathematical model of the physical entity equipment. The semi-physical loading and unloading machine simulator system does not need to adopt a design of 1:1 of the whole physical object, namely, prototype physical entity equipment such as a motor, an encoder, a sensor and the like is omitted, a simulation model of a set of unloading machine control console is not needed to be redesigned, a signal mathematical model of the physical entity equipment is built, a software program is utilized to generate a simulation signal and the simulation signal is fed back to the loading and unloading machine control console, so that the simulation signal can be still connected with the loading and unloading machine control console through a prefabricated cable with a quick-plug connector under the condition that a special storage room does not have the prototype physical entity equipment, and a complete material changing operation training system is built.
Specifically, the loader simulator system comprises an input signal acquisition module 13, a simulation signal generation module 14, a simulation signal output module 15, an upper computer data processing module 16, a parameter setting module 12 and an initialization module 11.
The input signal acquisition module 13 is used for receiving an analog quantity signal from a console of the loading and unloading machine and a switching value signal from an upper computer; including excitation signals from the servo driver, synchronous clock signals from the encoder interface module, handle control speed signals, and other switching value signals.
The simulation signal generating module 14 is configured to dynamically generate a simulation signal of the physical entity device in real time according to the input signal received by the input signal acquisition module 13; these simulation signals include all signals required to meet the hardware interface of the loader and unloader, including encoder gray code signals, motor rotary encoder signals, load sensor signals, and switching value simulation signals, etc.
The simulation signal output module 15 is used for outputting the generated simulation signal to the loading and unloading machine console in real time; in the process of outputting the simulation signals, the requirements of a hardware interface transmission protocol, transmission instantaneity (mu s level) and scanning sampling period are required to be met; the encoder gray code signal needs to detect the received synchronous clock signal to output the simulation signal, and the motor rotary encoder simulation signal needs to receive the excitation signal sent by the servo drive to continuously output.
The upper computer data processing module 16 is used for real-time data processing between the upper computer and the simulation signal generating module; the upper computer data processing module 16 can modify preset parameter values of different units; adjusting an encoder bias value; adjusting the load value and the load deviation value; setting/adjusting the playing speed of the three-dimensional model animation control; displaying the running state of the loading and unloading machine in real time; and sending out various operation fault simulation instructions of the loading and unloading machine. For example, the upper computer data processing module may preset/modify the loader cart and trolley zero coordinates; adjusting master/slave encoder bias values for the cart, trolley and master lift; adjusting the load values of the main lift and the television rod and the deviation values of the main lift main/auxiliary load sensors; setting/adjusting the playing speed of a three-dimensional model animation control of the loading and unloading machine; the control program is interacted with the network communication state, the loading and unloading machine running state and the encoder power supply state in real time; various operation fault conditions (such as encoder out-of-tolerance, overload/underload, gripper faults, sensor faults, brake faults and the like) of the loading and unloading machine are flexibly simulated.
A parameter setting module 12, configured to preset on-site operation parameters of the loader-unloader; the on-site operation parameters of the loading and unloading machine are two groups, the on-site operation parameters correspond to the on-site operation parameters of the loading and unloading machines of the two units respectively, and operators select/switch different preset parameters of the units according to requirements to complete the training of the material changing operation of the different units and the functional inspection of the electric components of the control console. The preset unit parameters comprise zero coordinates of a loading and unloading machine cart/trolley, full lower elevation of a main lifting (a reactor core area and a tipping area), main lifting load values (dry and wet states), television rod load values, overload/underload thresholds and boundary coordinates of a reactor core pool.
And the initialization module 11 is used for initializing assignment so as to output a default value to the loading and unloading machine console after the system is electrified, and ensuring that the whole refueling operation training system works in a normal state. The initialization assignment is carried out according to input signals required by a control system of the loading and unloading machine during normal operation. The initialization assignment comprises signals such as hand wheel limit, limit, safety limit, encoder initial value, load initial value, brake state, fixed sleeve limit, gripping apparatus engagement/release state and the like.
In this embodiment, the input signal acquisition module, the simulation signal generation module, the simulation signal output module, the parameter setting module, and the initialization module are all disposed in the programmable automation controller. The upper computer data processing module can be issued as an executable program file (EXE file) and installed in any touch screen with a windows operating system.
In this embodiment, the upper computer may be an industrial touch screen, and is connected to the programmable automation controller by using an ethernet, which is mainly used for displaying the real-time running state (including main lifting elevation, load and limit switch state) of the loading/unloading machine; sending out an operation fault simulation instruction of the loading and unloading machine; switching the operation parameters of loading and unloading machines of different units; and displaying the three-dimensional animation, the upper computer picture version information and the network communication state of the loading and unloading machine.
The switching value signal includes: the operator operates the handle, button or upper computer picture on the control console of the loader and the unloader, and sends out running direction command, gripping apparatus control command, encoder power state and interlocking signal between the loader and the fuel transfer device. The analog quantity signal includes: a speed set signal, an encoder clock signal, and a motor rotary encoder excitation signal.
The simulation signal comprises a switching value output signal and an analog value output signal; the switching value output signals comprise analog signals of a hand wheel, a safety limit, an anti-collision limit, a rope breakage limit and a brake band-type brake of the loading and unloading machine and/or a brake abrasion sensor of the loading and unloading machine; the analog output signal includes an encoder gray code, a motor resolver, and an analog signal of a load sensor.
The simulator system is pre-provided with the on-site operation parameters of the loading and unloading machines of the two nuclear power units, and operators can freely select/switch on the upper computer picture according to training requirements, so that not only is the training of the material changing process of the operators realized, but also the familiarity of the operators on the on-site operation parameters of the loading and unloading machines of different units is effectively improved.
The simulator system can complete the overall test and inspection of the performance of the electrical components in the loading and unloading machine control console before the major repair of the nuclear power unit, if the function of a certain component fails, the simulation training process of the loading and unloading operation can be interrupted, and at the moment, necessary fault prompt information can be given on the industrial touch screens of the loading and unloading machine control console and the loading and unloading machine simulator system, so that maintenance personnel can conveniently and quickly locate, search and replace the electrical components with functional failure.
It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention also include such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. The above embodiments are merely illustrative of the present invention, and the present invention may be embodied in other specific forms or with other specific forms without departing from the spirit or essential characteristics thereof. The described embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. The scope of the invention should be indicated by the appended claims, and any changes that are equivalent to the intent and scope of the claims are intended to be encompassed within the scope of the invention.
Claims (4)
1. The semi-physical loading and unloading machine simulator system based on the simulation technology is characterized by comprising a loading and unloading machine control console and a loading and unloading machine simulator system; the loading and unloading machine control console is connected with the loading and unloading machine simulator system through a quick-plug connector; the loading and unloading machine simulator system generates simulation signals according to a signal mathematical model of the physical entity equipment;
the loader simulator system comprises:
the input signal acquisition module is used for receiving analog quantity signals from a control console of the loading and unloading machine and switching value signals from an upper computer, and comprises excitation signals sent by a servo driver, synchronous clock signals sent by an encoder interface module, handle control speed signals and other switching value signals;
the simulation signal generation module is used for dynamically generating simulation signals of the physical entity equipment in real time according to the input signals received by the input signal acquisition module, wherein the simulation signals comprise all signals which are in line with the hardware interface of the loading and unloading machine control console;
the simulation signal output module is used for outputting the generated simulation signal to the loading and unloading machine control console in real time, and the hardware interface transmission protocol, the transmission instantaneity and the scanning sampling period requirements of the loading and unloading machine control console are required to be met in the simulation signal output process;
the upper computer data processing module is used for real-time data processing between the upper computer and the simulation signal generating module, the data processing module can modify preset parameters of the unloading machine assembled by different nuclear motors, adjust encoder deviation set values, load values and load deviation set values, set/adjust the play speed of the three-dimensional animation control of the loading and unloading machine, display the running state of the loading and unloading machine in real time and send out various running fault simulation instructions of the loading and unloading machine;
the parameter setting module is used for presetting site operation parameters of the loading and unloading machine, wherein the site operation parameters of the loading and unloading machine are two groups, parameter values are completely consistent with actual measured physical parameters of reactor cores of the loading and unloading machines of the two units respectively, different unit preset parameters are selected/switched according to requirements, and the material changing operation training of different units and the functional inspection of electric components of a control console of the loading and unloading machine are completed, so that the integral test and the periodic inspection of the performance of the electric components in the control console of the loading and unloading machine are completed before the material changing overhaul of the nuclear power unit, and failure electric components are found and replaced in time; the preset parameters comprise zero coordinates of a cart/trolley of the loading and unloading machine, full lower elevation of main lifting, main lifting load values, television rod load values, overload/underload thresholds and boundary coordinates of a reactor core pool;
the initialization module is used for initializing assignment to output a default value to a control console of the loading and unloading machine after the system is electrified, so that the whole material changing operation training system is ensured to work in a normal state, and the initialization assignment comprises a hand wheel limit, a limit, a safety limit, an encoder initial value, a load initial value, a brake state, a fixed sleeve limit and a gripping apparatus meshing/tripping state.
2. The simulation system of the semi-physical loading and unloading machine based on the simulation technology according to claim 1, wherein the switching value signal comprises: the operator operates the handle, button or upper computer picture on the control console of the loader and the unloader, and sends out running direction command, gripping apparatus control command, encoder power state and interlocking signal between the loader and the fuel transfer device.
3. The simulation technology-based semi-physical loader-unloader simulator system of claim 1, wherein said analog signal comprises: a speed set signal, an encoder clock signal, and a motor rotary encoder excitation signal.
4. The simulation technology-based semi-physical loading and unloading machine simulator system of claim 1, wherein the simulation signals comprise a switching value output signal and an analog value output signal; the switching value output signals comprise analog signals of a hand wheel, a safety limit, an anti-collision limit, a rope breakage limit and a brake band-type brake of the loading and unloading machine and/or a brake abrasion sensor of the loading and unloading machine; the analog output signal includes an encoder gray code, a motor resolver, and an analog signal of a load sensor.
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