CN114137851A

CN114137851A - Fault simulation system for engine test run system

Info

Publication number: CN114137851A
Application number: CN202111393227.3A
Authority: CN
Inventors: 孔德斌; 王园丁; 王明迪; 李慧; 王慧娟; 董鹏飞; 赵春辉; 贺勇; 董雨田
Original assignee: Chongqing Weizhe Technology Co ltd; Shanghai Institute of Space Propulsion
Current assignee: Chongqing Weizhe Technology Co ltd; Shanghai Institute of Space Propulsion
Priority date: 2021-11-23
Filing date: 2021-11-23
Publication date: 2022-03-04

Abstract

The invention discloses a fault simulation system for an engine test run system, which comprises a user operation interface and an entity control panel, wherein the entity control panel comprises upper-level software and a manual control panel, the software realizes the measurement and control function of a test bed, and the manual control panel is used for debugging or handling sudden conditions; the intelligent measurement and control system server: collecting all data on the test bed, and controlling the test bed according to the test task and the test flow; the platform driver is mainly used for controlling the modular device of the PXI modular platform; the invention provides a high-performance modular instrument and rich I/O (input/output), wherein the I/O has a special synchronization function and a main software function and is suitable for test measurement applications from equipment inspection to automatic production test and the like; the system adopts a PXI system platform, provides various performance and appearance structure choices and wide I/O, and can help to reduce risks, improve system performance and simplify the design of an advanced embedded control and monitoring system.

Description

Fault simulation system for engine test run system

Technical Field

The invention relates to the technical field of engine test run systems, in particular to a fault simulation system for an engine test run system.

Background

The test bed of the rocket engine has long development period, high cost and great danger, so the test health management system can be formally applied to the test of the liquid rocket engine after corresponding test verification. At present, many fault diagnosis systems utilize a static model of an engine test bed and are primarily applied, such as a fault diagnosis system based on a linear static model and a fault diagnosis system based on a nonlinear static model and a component model, which are realized by using a linear regression theory. In addition, the diagnostic reasoning technology based on the system model is an important branch of the model-based diagnostic method, and the main idea is to establish a diagnostic model of the system, determine a set of components causing system faults by using a logical reasoning theory according to the input of the system and the actual behavior of the observation system, and simulate and edit fault signals by means of hardware in a ring.

The development of a hardware-in-loop simulation system for a fault diagnosis algorithm at home and abroad has achieved remarkable results, a rapid prototyping simulation platform which is universal and takes an engine test bed as a control object is developed, and seamless conversion of the control system algorithm from digital simulation to semi-physical simulation is effectively achieved. However, these platforms also lack corresponding general operational specifications and a unified evaluation system for various fault diagnosis algorithms, so that the actual engineering application of the platforms is greatly limited.

On the other hand, some existing fault simulation systems are only applicable to a single engine; reliability and stability are poor. The design architecture is complex, and the operability and maintainability of the system are low.

Disclosure of Invention

In order to overcome the defects in the prior art, the invention provides a fault simulation system for an engine test run system.

In order to achieve the purpose, the invention provides the following technical scheme:

a fault simulation system for an engine test run system is divided into four layers:

user operation interface and entity control panel: the test bench comprises upper-level software and a manual control panel, wherein the software realizes the measurement and control function of the test bench, and the manual control panel is used for debugging or processing emergency conditions;

the intelligent measurement and control system server: collecting all data on the test bed, and controlling the test bed according to the test task and the test flow;

a platform driver: the method mainly realizes the control of modular equipment for a driver of the PXI modular platform; integrating a Microsoft Visual Studio platform;

PXI system: the PXI cabinet is internally provided with a PXI controller, a pressure signal simulation card, a thermocouple simulation card, a valve current simulation card, a digital multimeter, a simulation acceleration card, a valve load simulator and a 485 communication card.

Preferably, the PXI chassis has 10 slots, 7 hybrid slots, 1 PXI Express system timing slot, and 1 peripheral expansion slot; the model of the PXI case is PXIe-1092, each slot is provided with a high-bandwidth backboard and a 82W power supply and cooling function to meet various high-performance test and measurement application requirements, each slot of the full-hybrid backboard can support a PXIExpress module, 7 slots can support a PXI hybrid compatible module, and therefore the PXI hybrid compatible module has great flexibility in placement of instrument modules, and also provides timing and synchronization options, wherein the PXI hybrid compatible module comprises a built-in oven controlled crystal oscillator (OCXO); the peripheral expansion slot is used for providing power for the multi-slot-width module.

The PXI controller is a 2.7Gz dual-core or 2.6GHz four-core processor PX controller; including two 10/10/100BASE-TX (gigabit) ethernet ports, two USB 3.0 ports and four USB20 ports, as well as one integrated hard drive, serial port and other peripheral I/O.

The pressure signal simulation card is a PXI model output module with 16 bits, 8 channels and 250kS/s channel isolation; the inter-channel separation analog output module with the integrated signal conditioning function. The device provides accurate, synchronous dynamic voltage and current output; by integrating signal conditioning and digital-to-analog converters on the same device.

The valve current simulation card is a 16-bit 32-channel 1MS/s PXI simulation output module; also included are 10 digital I/0 lines, 4 counters/timers, digital triggers and advanced timing.

The analog accelerator card is a PXI digital reconfigurable I/O module, is provided with a user programmable FPGA and is used for onboard processing and flexible I0 operation; the synchronization and timing of all signals and operations can be fully controlled, as well as custom on-board decisions.

The valve load simulator is a 32-channel Al, 4-channel AO, 48-channel DIO and PXI multifunctional I/0 module; analog I/0, digital/0 and four 32-bit counters/timers are provided for PWM, encoder, frequency, event counting; including separate analog and digital timing engines and re-triggerable measurement tasks.

Thermocouple simulation card: the module is a low-pressure 32-channel output module and can also have 24, 16 or 8 channels; provides a low voltage output through two connector pins, is capable of providing ± 20mV and 0.7 μ V resolution, ± 50mV and ± 100mV and 3.3 μ V resolution, covering most thermocouple types; the use of two wire outputs and isolation from ground ensures that the thermocouple analog card can be used to accurately simulate low voltages even if there is a common mode voltage in the system; each Vcold connection is independent, allowing multiple cold connections to be connected. To improve accuracy, each channel of the low voltage output carries accurate calibration data stored in the EEPROM on the module, without the need to calibrate the channel periodically.

A digital multimeter: 6% bit, 300V, onboard 1.8MS/s isolation digitizer; the measurement functions of two common test instruments are provided: high resolution DMM and digitizer; as a DMM, PXle-4080 provides fast and accurate AC/DC voltage, AC/DC current, 2-wire or 4-wire resistance, frequency/cycle measurements, and two-tube testing.

485 communication card: 8 ports, RS485/RS422PX rich line interface module; the high-performance interface is used for carrying out high-speed communication with RS485 and RS422 equipment, and has high-performance DMA transmission, multithreading and multi-processor support; the NI serial interface may also be used as a standard COM port to accommodate programs using serial communication.

The invention has the technical effects and advantages that:

1. PXI is a robust PC-based measurement and automation platform promulgated by the PXI consortium. PXI combines the electrical bus characteristics of PCI (Peripheral Component interconnect) with the robustness, modularity, and Eurocard mechanical packaging characteristics of CompactPCI (compact PCI) to develop mechanical, electrical, and software specifications suitable for testing, measurement, and data acquisition applications. The PXI system provides high-performance modular instruments and rich I/O (input/output) which has a special synchronization function and a main software function and is suitable for test and measurement applications from equipment inspection to automatic production test and the like.

2. A platform driver: the method mainly realizes the control of modular equipment for a driver of the PXI modular platform; the Microsoft Visual Studio platform is integrated, so that programming debugging by adopting IEC 61131-3 and C/C + + is more convenient. Functional blocks written by different languages can exchange data and call each other;

3. the PXI system platform is adopted in the system, the firm PXI platform is subjected to industrial certification testing and other various tests including wide-range temperature testing, thermal testing, EMC/ESD testing and impact and vibration testing, firm and durable reliable system PXI platform with highly integrated software can be deployed, various performance and appearance structure choices and wide I/O are provided, risks can be reduced, system performance is improved, and the design of an advanced embedded control and monitoring system is simplified.

Drawings

FIG. 1 is a schematic diagram of the system of the present invention.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

PXI (PCI extensions for Instrumentation, instrument system oriented PCI extension) is a robust PC-based measurement and automation platform promulgated by the PXI consortium.

As shown in fig. 1, the system for simulating the fault of the engine test system has four layers:

a platform driver: the method mainly realizes the control of modular equipment for a driver of the PXI modular platform; the Microsoft Visual Studio platform is integrated, so that programming debugging by adopting IEC 61131-3 and C/C + + is more convenient, and functional blocks written by different languages can exchange data and call each other;

The PXI case is provided with 10 slots, wherein 7 hybrid slots, 1 PXI Express system timing slot and 1 peripheral expansion slot are formed in the PXI case; the PXI case is in a PXIe-1092 model, each slot is provided with a high-bandwidth backboard and a 82W power supply and cooling function so as to meet various high-performance test and measurement application requirements, each slot of the full-hybrid backboard can support a PXI Express module, and 7 slots can support a PXI hybrid compatible module, so that the placement of instrument modules is greatly flexible, and the PXI hybrid compatible module also provides timing and synchronization options, wherein the PXI hybrid compatible module comprises a built-in oven controlled crystal oscillator (OCXO); the peripheral expansion slot is used for providing power for the multi-slot-width module.

The PXI controller is a 2.7Gz dual-core or 2.6GHz four-core processor PX controller-PXe-8840 which is a blowing-in controller for a P-wind system and is suitable for processor-intensive and modular instruments and data acquisition application. PXe-8840 contains two 10/10/100BASE-TX Ethernet ports, two USB 3.0 ports and four USB20 ports and one integrated hard drive, serial port and other peripheral I/O.

The pressure signal simulation card is a PXI model output module with 16 bits, 8 channels and 250kS/s channel isolation; the model is PXe-4322, which is an interchannel isolated analog output module with integrated signal conditioning function. The device provides accurate, synchronized dynamic voltage and current output. By integrating signal conditioning and digital-to-analog converters on the same device, the PXle-4322 isolated input module has a smaller volume and higher measurement performance. In the current mode, the module operates in four quadrants, thus drawing current as well as sinking current.

The valve current analog card is a 16-bit 32-channel 1MS/s PXI analog output module-PXle-6738 high-density analog output module. The device is an ideal choice for applications such as high-density excitation-response testing and open-loop simulation. The maximum sampling rate can be achieved using up to 16 channels, each of which needs to be in a different group. PXle-6738 also includes 10 digital I/0 lines, 4 counters/timers, digital triggers and advanced timing to meet various application requirements. The digital triggering and PXIe synchronization capabilities of the modules enable them to be coupled to more data collection, sports, and vision products, helping users build highly customized measurement solutions to test innovative designs.

The analog accelerator card, PXI digital reconfigurable I/O module has a user programmable FPGA for on-board processing and flexible I0 operation. The synchronization and timing of all signals and operations can be fully controlled, as well as custom on-board decisions. PXI digital reconfigurable I/O modules are suitable for a variety of applications, such as high-speed waveform generation, sensor simulation, hardware-in-the-loop (L) testing, custom communication protocols, bit error rate testing, and other applications requiring precise timing and control.

Valve load simulator: PXle, 32-way Al (16 bits, 2MS/s), 4-way AO, 48-way DIO, PXI multifunctional I/0 module-PXle-6363 provide analog I/0, digital/0 and four 32-bit counters/timers for PWM, encoder, frequency, event counting and other applications. The device provides high performance functionality using a high throughput PCI Express bus and multi-core optimized drivers and application software. Onboard NI-STC3 timing and synchronization technology provides advanced timing functions including independent analog and digital timing engines and re-triggerable measurement tasks. PXle-6363 is suitable for a wide range of applications from basic data recording to control and test automation. The accompanying NI-DAQmx driver and configuration utility simplify configuration and measurement.

Thermocouple simulation card: 41-761-001 is a low pressure 32 channel output module well suited for simulating thermocouple operation, and may have 24, 16, or 8 channels. Each channel of 41-761 provides a low voltage output through two connector pins capable of providing a ± 20mV and 0.7 μ V resolution, a ± 50mV and ± 100mV and a 3.3 μ V resolution, covering most thermocouple types. Using two-wire outputs and isolation from ground ensures that 41-761 can be used to accurately simulate low voltages even if common mode voltages are present in the system. Each Vcold connection is independent, allowing 41-761 to connect multiple cold connections. To improve accuracy, each channel of low voltage output carries accurate calibration data stored in the EEPROM on the module. There is no need to calibrate the channel periodically.

A digital multimeter: PXle, 6% bit, +/-300V, board-mounted 1.8MS/s isolation digitizer, PXI digital multimeter PXle-4080 is a high-performance 6% bit 300VDMM, providing the measurement functions of two common test instruments: high resolution DMMs and digitizers. As a DMM, PXle-4080 provides fast and accurate AC/DC voltage, AC/DC current, 2-wire or 4-wire resistance, frequency/cycle measurements, and two-tube testing.

485 communication card: the 8-port, RS485/RS422PX redundant interface module-PX 1-8431/8 is a high performance interface for high speed communication with RS485 and RS422 devices, with high performance DMA transfer, multi-threading, and multi-processor support. The user may select either 4-wire or 2-transceiver mode to enable full-duplex or half-duplex communication. The NI serial interface may also be used as a standard COM port to accommodate programs using serial communication.

The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that are within the spirit and principle of the present invention are intended to be included in the scope of the present invention.

Claims

1. The utility model provides a fault simulation system for engine system of taking a trial run which characterized in that: the system is divided into four layers:

2. The fault simulation system for the engine test-run system according to claim 1, wherein: the PXI case is provided with 10 slots, wherein 7 hybrid slots, 1 PXI Express system timing slot and 1 peripheral expansion slot are formed in the PXI case; the model of the PXI case is PXIe-1092, each slot is provided with a high-bandwidth backboard and a 82W power supply and cooling function so as to meet various high-performance test and measurement application requirements, each slot of the full hybrid backboard can support a PXIExpress module, 7 slots can support a PXI hybrid compatible module, the PXI hybrid compatible module also provides timing and synchronization options, and the PXI hybrid compatible module comprises a built-in constant temperature crystal oscillator; the peripheral expansion slot is used for providing power for the multi-slot-width module.

3. The fault simulation system for the engine test-run system according to claim 1, wherein: the PXI controller is a 2.7Gz dual-core or 2.6GHz four-core processor PX controller; including two 10/10/100BASE-TX (gigabit) ethernet ports, two USB 3.0 ports and four USB20 ports, as well as one integrated hard drive, serial port and other peripheral I/O.

4. The fault simulation system for the engine test-run system according to claim 1, wherein: the pressure signal simulation card is a PXI model output module with 16 bits, 8 channels and 250kS/s channel isolation; the inter-channel separation analog output module with the integrated signal conditioning function. The device provides accurate, synchronous dynamic voltage and current output; by integrating signal conditioning and digital-to-analog converters on the same device.

5. The fault simulation system for the engine test-run system according to claim 1, wherein: the valve current simulation card is a 16-bit 32-channel 1MS/s PXI simulation output module; also included are 10 digital I/0 lines, 4 counters/timers, digital triggers and advanced timing.

6. The fault simulation system for the engine test-run system according to claim 1, wherein: the analog accelerator card is a PXI digital reconfigurable I/O module, is provided with a user programmable FPGA and is used for onboard processing and flexible I0 operation; the synchronization and timing of all signals and operations can be fully controlled, as well as custom on-board decisions.

7. The fault simulation system for the engine test-run system according to claim 1, wherein: the valve load simulator is a 32-channel Al, 4-channel AO, 48-channel DIO and PXI multifunctional I/0 module; analog I/0, digital/0 and four 32-bit counters/timers are provided for PWM, encoder, frequency, event counting; including separate analog and digital timing engines and re-triggerable measurement tasks.

8. The fault simulation system for the engine test-run system according to claim 1, wherein: thermocouple simulation card: the module is a low-pressure 32-channel output module and can also have 24, 16 or 8 channels; provides a low voltage output through two connector pins, is capable of providing ± 20mV and 0.7 μ V resolution, ± 50mV and ± 100mV and 3.3 μ V resolution, covering most thermocouple types; the use of two wire outputs and isolation from ground ensures that the thermocouple analog card can be used to accurately simulate low voltages even if there is a common mode voltage in the system; each Vcold connection is independent, allowing multiple cold connections to be connected. To improve accuracy, each channel of the low voltage output carries accurate calibration data stored in the EEPROM on the module, without the need to calibrate the channel periodically.

9. The fault simulation system for the engine test-run system according to claim 1, wherein: the digital multimeter is characterized in that: 6% bit, 300V, onboard 1.8MS/s isolation digitizer; the measurement functions of two common test instruments are provided: high resolution DMM and digitizer; as a DMM, PXle-4080 provides fast and accurate AC/DC voltage, AC/DC current, 2-wire or 4-wire resistance, frequency/cycle measurements, and two-tube testing.

10. The fault simulation system for the engine test-run system according to claim 1, wherein: the 485 communication card: 8 ports, RS485/RS422PX rich line interface module; the high-performance interface is used for carrying out high-speed communication with RS485 and RS422 equipment, and has high-performance DMA transmission, multithreading and multi-processor support; the NI serial interface may also be used as a standard COM port to accommodate programs using serial communication.