CN114488998A - Automatic test method for fault protection logic of control unit of traction inverter - Google Patents
Automatic test method for fault protection logic of control unit of traction inverter Download PDFInfo
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
- G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
- G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
- G05B23/0213—Modular or universal configuration of the monitoring system, e.g. monitoring system having modules that may be combined to build monitoring program; monitoring system that can be applied to legacy systems; adaptable monitoring system; using different communication protocols
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/24—Pc safety
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Abstract
The invention belongs to the technical field of traction inverter control unit fault identification and fault protection, in particular to a traction inverter control unit fault protection logic automatic test method, which solves the technical problems in the background technology and comprises an upper computer, a simulator, an automatic test system and a high-speed data acquisition system. Signals acquired by a high-speed data acquisition system are used as input conditions of automatic testing, the voltage and current trend under the fault working condition can be reflected in real time, and the fault logic protection strategy can be verified more accurately; and for products needing verification in batches, the automatic testing software is more efficient and accurate. The method can find the design deficiency and the leak of the fault protection logic in the early development of software and hardware of the traction inverter control unit, and improve the reliability of product design; and the method for automatically testing can quickly and efficiently verify the fault protection logic of the inverter control unit, is suitable for quickly verifying batch products, and shortens the research and development period of the products.
Description
Technical Field
The invention belongs to the technical field of traction inverter control unit fault identification and fault protection, and particularly relates to a traction inverter control unit fault protection logic automatic test method.
Background
With the rapid development of high-speed trains all over the world, the problem of safe and reliable operation becomes one of the important concerns of research and development engineers. The train traction inverter system is used as a main power source of the train and is also one of main sources of high-speed train faults. The traction inverter control unit controls the brain of the inverter, and when the traction inverter breaks down, the traction control unit can quickly and effectively identify the fault type and make corresponding fault protection actions, so that the traction inverter is protected from the situations of device damage, machine breakage and the like caused by the failure. Therefore, the design of the traction inverter and motor fault logic protection part is necessary and necessary on a software program for the reliability and safety of the system before the traction inverter control unit is loaded and operated.
At present, after a software program is written and loaded into a hardware control unit, there are two schemes for verifying the fault protection logic of a traction inverter system, as shown below.
The first method is to input certain voltage or current to corresponding collecting channels of the traction control unit by using an external voltage source or current source, and after the voltage and the current input from the outside exceed the threshold value in the program setting, corresponding fault logic protection strategies are executed, so that all fault protection logics are tested one by one. The disadvantages of this solution are: 1) in the test, only the low-voltage test of the traction control unit channel is carried out, the high-voltage test of the control unit and the controlled object cannot be simulated, and the real environment of the system under the fault working condition cannot be reflected; 2) by manually inputting the voltage and current values, test inaccuracy caused by manual input difference can occur; 3) when a plurality of samples need to be tested, the method is relatively complicated and the testing efficiency is relatively low.
And the second method is to carry out fault protection logic test by building a traction inverter system bench test. The method needs to build a real high-voltage bench test of the traction control unit and the traction inverter system, and carries out fault logic protection test by artificially triggering faults. The disadvantages of this solution are: 1) the testing method needs to manually build a testing table, and is time-consuming and labor-consuming. And under the condition that the test resources are insufficient, the test can be carried out only by waiting for the release of the test resources; 2) fault logic protection tests are carried out through a bench test, and some fault logic protection tests can cause damage to system devices due to insufficient software or hardware design, so that research and development production cost can be increased; 3) when a product has a batch order, the fault logic protection test of each product is required to be performed through a bench test, which increases the product lead time.
Disclosure of Invention
The invention aims to solve the technical problems and provides an automatic test method for the fault protection logic of a traction inverter control unit. The method can find the design deficiency and the leak of the fault protection logic in the early development of software and hardware of the traction inverter control unit, and improve the reliability of product design; and the method for automatically testing can quickly and efficiently verify the fault protection logic of the inverter control unit, is suitable for quickly verifying batch products, and shortens the research and development period of the products.
The technical means for solving the technical problems of the invention is as follows: a traction inverter control unit fault protection logic automatic test method comprises the following steps:
step one, building a semi-physical simulation model of a main circuit of a traction inverter system in an upper computer;
secondly, combing faults of the traction inverter system and establishing a fault tree, building a fault model in the main circuit semi-physical simulation model built in the first step according to the fault tree and setting fault triggering conditions, entering the fault model under the condition of ensuring fault triggering, and under the condition of not triggering, normally working the main circuit semi-physical simulation model of the traction inverter system;
thirdly, the upper computer is connected with the simulator through an Ethernet switch, and the upper computer configures and compiles the model built in the second step to generate an executable file and downloads the executable file to a board card of the simulator; the upper computer is crosslinked with the simulation machine, and the simulation model in the simulation machine is controlled and monitored in parameters;
fourthly, the simulator is connected to the traction inverter control unit TCU through the signal conditioning system, the BOB system and the signal adapting system in sequence, and hardware connection of the simulator and a traction inverter control unit TCU real object is completed;
step five, compiling an action time sequence when the traction inverter control unit TCU carries out fault protection after the traction inverter system has a fault according to the fault tree and the inverter fault protection logic, and generating an inverter fault protection logic list;
compiling an automatic test sequence in an automatic test system according to the inverter fault protection logic list compiled in the step five;
step seven, automatic testing joint debugging of traction inverter fault protection logic: the automatic test system runs an automatic test sequence, the automatic test system sends a fault working condition trigger signal to a simulation model in the simulator, the fault trigger condition is met and enters the fault model, the traction inverter control unit TCU judges fault information according to voltage, current, contactor state, temperature and rotating speed signals fed back by the simulator at the moment, a production feedback fault word is sent to the simulator, the simulator sends the fault word to the automatic test system as a first input condition for automatic judgment, the traction inverter control unit TCU also outputs a corresponding PWM wave, and the PWM wave is input into the simulation model through the signal adaptation system, the BOB system and the signal conditioning system to carry out closed-loop control;
step eight, the high-speed data acquisition system acquires voltage, current, driving/feedback pulse signals and commands and state signals of the contactor/relay from the BOB system through hard wires, and transmits the driving/feedback pulse signals and the commands and state signals of the contactor/relay to the automatic test system through the Ethernet, and the driving/feedback pulse signals and the commands and state signals of the contactor/relay serve as second input conditions of automatic test criteria to be used for automatic judgment;
step nine, the automatic test system judges according to the input first input condition, the input second input condition and the inverter fault protection logic list: if the test result meets the criterion condition, the automatic test system judges Pass, otherwise, the test result is Fail, and finally, an automatic test report is output.
The signal conditioning system functions as follows: because the output signal of the simulator board card is a voltage signal of +/-10 v, the signal mode and amplitude required by a TCU (traction inverter control unit) cannot be met, a signal conditioning system is required to be accessed to convert the voltage signal into a signal required by the TCU; the signal parameter output by the signal conditioning system is a signal required by the TCU, so that the BOB system is added for conveniently acquiring the signal by the high-speed acquisition system without influencing other systems, and the BOB system is a breakpoint test system; because the TCU needs more signals and the signal modes are different, a signal adaptation system is designed, and the signal wiring harness is sorted and classified under the action of the signal adaptation system, so that the TCU is convenient to access and debug in the later period. The upper computer is used for simulation engineering configuration, simulation parameter control and data acquisition monitoring; the automatic test system can automatically prepare test cases, execute the test cases and output automatic test reports; the high-speed data acquisition system can acquire analog quantity signals, acquire digital quantity signals and transmit the signals to the automatic test system.
The automatic testing system sends a fault working condition starting signal to a simulation model in the simulator, the simulation model enters the fault model after receiving a trigger signal and generates a series of corresponding output signals, the simulator sends the signals of the simulation model to the TCU through the signal conditioning system, the BOB system and the signal adapting system, the TCU judges fault information according to voltage, current, contactor state, temperature and rotating speed signals fed back by the simulator at the moment, and the traction inverter control unit TCU outputs a corresponding PWM wave and inputs the PWM wave into the simulation model through the signal adapting system, the BOB system and the signal conditioning system to perform closed-loop control; the TCU produces and feeds back fault words and sends the fault words to the simulator, the simulator sends the fault words to the automatic test system, and the high-speed data acquisition system sends acquired signals to the automatic test system, so that closed-loop control is formed between the automatic test system and the simulation system, and automatic test is realized. The method is suitable for rapid verification of batch products, and shortens the product research and development period.
The beneficial effects of the invention are: the main circuit and the fault model are split by adopting a block modeling mode, and all parts are connected after being modeled respectively, so that hardware resources are saved, and the modeling difficulty is reduced; when the fault logic protection strategy needs to be verified, only the fault model needs to be switched to without recompiling and downloading the whole model, so that the method is convenient and fast; the sampling rate of the high-speed data acquisition system can reach 1M/S, signals acquired by the high-speed data acquisition system are used as input conditions of automatic testing, the voltage and current trend under the fault working condition can be reflected in real time, and the fault logic protection strategy can be verified more accurately; and for products needing verification in batches, the automatic testing software is more efficient and accurate. The method can find the design deficiency and the leak of the fault protection logic in the early development of software and hardware of the traction inverter control unit, and improve the reliability of product design; and the method for automatically testing can quickly and efficiently verify the fault protection logic of the inverter control unit, is suitable for quickly verifying batch products, and shortens the research and development period of the products.
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In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
Fig. 1 is a schematic diagram of a traction inverter control unit logic protection test hardware connection.
Fig. 2 is a schematic flow chart of an automated testing method for the fault protection logic of the traction inverter control unit according to the present invention.
Fig. 3 is a schematic diagram of a traction inverter fault tree according to the present invention.
Fig. 4 is a table listing inverter fault protection logic.
FIG. 5 is a flow chart of automated testing in an embodiment.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the accompanying drawings, and it should be understood that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
A method for automatically testing a traction inverter control unit fault protection logic, as shown in fig. 1 and 2, includes the following steps:
in the upper computer, a main circuit semi-physical simulation model of a traction inverter system is built by applying an FPGA language in Matlab software, the traction inverter system comprises a direct-current bus, an inverter, a motor and a contactor/relay model, the simulation precision can reach ns level, and the system simulation precision is ensured; after the semi-physical simulation model of the main circuit of the traction inverter system is built, off-line debugging is carried out, the step II is carried out only after the off-line debugging is passed, and otherwise, the model is built again by returning to the step I;
step two, combing faults of the traction inverter system and establishing a fault tree, as shown in fig. 3, building a fault model in the main circuit semi-physical simulation model built in the step one according to the fault tree and setting a fault triggering condition, ensuring that the main circuit semi-physical simulation model enters the fault model under the condition of fault triggering, and under the condition of no triggering, normally working the main circuit semi-physical simulation model of the traction inverter system; performing off-line debugging, entering the third step after the off-line debugging is passed, and returning to the step to rebuild the model if the off-line debugging is passed; the fault tree comprises a direct current bus link fault, an inverter link fault, a motor link fault and a contactor/relay fault; the direct current bus link faults comprise intermediate direct current side overvoltage faults, intermediate direct current side undervoltage faults, intermediate direct current loop short-circuit faults and intermediate direct current ground faults, and the intermediate direct current ground faults comprise intermediate direct current positive pole ground faults and intermediate direct current negative pole ground faults; the inverter link faults comprise an inversion U-phase driving fault, an inversion V-phase driving fault, a W-phase driving fault, an inversion output overcurrent fault and an inversion side grounding fault; the motor link faults comprise a motor phase loss fault, a motor non-working fault, a motor over-temperature fault and a motor over-speed fault; the contactor/relay faults comprise a contactor/relay clamping fault and a contactor/relay clamping fault;
thirdly, the upper computer is connected with the simulator through an Ethernet switch, and the upper computer configures and compiles the model built in the second step to generate an executable file and downloads the executable file to a board card of the simulator; the upper computer is crosslinked with the simulation machine, and the simulation model in the simulation machine is controlled and monitored in parameters; the method comprises the following specific steps: 1) compiling and downloading of simulation models: after the simulation model is built and off-line debugged, the simulation model is configured and compiled on the upper computer by using Higale code generation and compilation control software HiGale-Target to generate an executable file, and the executable file is downloaded into a board card of the simulation machine; 2) on an upper computer, an interface is integrated in a Simulink environment, and control and parameter monitoring of a simulation model are realized by configuring relevant parameters of a Simulink code generation tool Simulink code and cross-linking the control and monitoring interface matched with a simulation machine;
fourthly, the simulator is connected to the traction inverter control unit TCU through the signal conditioning system, the BOB system and the signal adapting system in sequence, and hardware connection of the simulator and the traction inverter control unit TCU is completed; the signal conditioning system functions as follows: because the output signal of the simulator board card is a voltage signal of +/-10 v, the signal mode and amplitude required by a TCU (traction inverter control unit) cannot be met, a signal conditioning system is required to be accessed to convert the voltage signal into a signal required by the TCU; the signal parameter output by the signal conditioning system is a signal required by the TCU, so that the BOB system is added for conveniently acquiring the signal by the high-speed acquisition system without influencing other systems, and the BOB system is a breakpoint test system; because the TCU needs more signals and the signal modes are inconsistent, a signal adaptation system is designed, and the signal adaptation system has the functions of sorting and classifying the signal wire harness, so that the TCU is conveniently accessed and later-stage debugging is facilitated;
step five, writing an action time sequence when the traction inverter control unit TCU carries out fault protection after the traction inverter system has a fault according to the fault tree and the inverter fault protection logic, and generating an inverter fault protection logic list as shown in FIG. 4;
step six, compiling an automatic test sequence according to the action time sequence during fault protection in the robaint automatic test system according to the inverter fault protection logic list compiled in the step five (corresponding pulse action, relay or contactor action after different faults);
step seven, automatic testing joint debugging of the traction inverter fault protection logic: the automatic test system runs an automatic test sequence, the automatic test system sends a fault working condition trigger signal to a simulation model in the simulator through the Ethernet, a fault trigger condition is met and enters the fault model, the traction inverter control unit TCU judges fault information according to a voltage, current, contactor state, temperature and rotating speed signal fed back by the simulator at the moment, a production feedback fault word is sent to the simulator through an MVB protocol, the simulator sends the fault word to the automatic test system through the Ethernet to serve as a first input condition for automatic judgment, the traction inverter control unit TCU also outputs a corresponding PWM wave (pulse drive signal), and the PWM wave is input into the simulation model through the signal adapting system, the BOB system and the signal conditioning system to carry out closed-loop control;
step eight, the high-speed data acquisition system acquires voltage, current, driving/feedback pulse signals and commands and state signals of the contactor/relay from the BOB system through hard wires, and transmits the driving/feedback pulse signals and the commands and state signals of the contactor/relay to the automatic test system through the Ethernet, and the driving/feedback pulse signals and the commands and state signals of the contactor/relay are used as second input conditions of automatic test criteria for automatic judgment;
step nine, the automatic test system judges according to the input first input condition, the second input condition and the inverter fault protection logic list: if the standard conditions are met, the automatic test system judges Pass, otherwise, the automatic test system judges Fail, and finally, an automatic test report is output.
Fig. 5 illustrates a flow of programming an automation program by taking an example of an overcurrent fault output by the traction inverter:
(1) determining an inverter output overcurrent fault logic time sequence;
(2) reading signals such as contactor state, pulse state and the like of a high-speed data acquisition system (high-speed data acquisition software), and connecting fault trigger instruction control parameters and fault word parameters of semi-physical simulation access;
(3) adding criteria according to the inverter fault protection logic list: after the inverter outputs the overcurrent, the inversion pulse is blocked, the contactor does not act, and the fed back fault word is 0 xXX;
(4) after performing the automated test, the input signal is compared to a criterion;
(5) if the input is the same as the criterion, the test result is judged to be Pass, if the input is not the same as the criterion, the test result is judged to be Fail, and the problem is searched after the test.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit the same; while the invention has been described in detail and with reference to the foregoing embodiments, it will be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (8)
1. A traction inverter control unit fault protection logic automatic test method is characterized by comprising the following steps:
step one, building a semi-physical simulation model of a main circuit of a traction inverter system in an upper computer;
step two, combing faults of the traction inverter system and establishing a fault tree, building a fault model in the main circuit semi-physical simulation model built in the step one according to the fault tree and setting fault triggering conditions, entering the fault model under the condition of ensuring fault triggering, and under the condition of not triggering, drawing the main circuit semi-physical simulation model of the traction inverter system to normally work;
thirdly, the upper computer is connected with the simulator through an Ethernet switch, and the upper computer configures and compiles the model built in the second step to generate an executable file and downloads the executable file to a board card of the simulator; the upper computer is crosslinked with the simulation machine, and the simulation model in the simulation machine is controlled and monitored in parameters;
fourthly, the simulator is connected to the traction inverter control unit TCU through the signal conditioning system, the BOB system and the signal adapting system in sequence, and hardware connection of the simulator and the traction inverter control unit TCU is completed;
step five, compiling an action time sequence when the traction inverter control unit TCU carries out fault protection after a traction inverter system has a fault according to the fault tree and the inverter fault protection logic, and generating an inverter fault protection logic list;
compiling an automatic test sequence in an automatic test system according to the inverter fault protection logic list compiled in the step five;
step seven, automatic testing joint debugging of the traction inverter fault protection logic: the automatic test system runs an automatic test sequence, the automatic test system sends a fault working condition trigger signal to a simulation model in the simulator, the fault trigger condition is met and enters the fault model, the traction inverter control unit TCU judges fault information according to voltage, current, contactor state, temperature and rotating speed signals fed back by the simulator at the moment, a production feedback fault word is sent to the simulator, the simulator sends the fault word to the automatic test system as a first input condition for automatic judgment, the traction inverter control unit TCU also outputs a corresponding PWM wave, and the PWM wave is input into the simulation model through the signal adaptation system, the BOB system and the signal conditioning system to carry out closed-loop control;
step eight, the high-speed data acquisition system acquires voltage, current, driving/feedback pulse signals and commands and state signals of the contactor/relay from the BOB system through hard wires, and transmits the driving/feedback pulse signals and the commands and state signals of the contactor/relay to the automatic test system through the Ethernet, and the driving/feedback pulse signals and the commands and state signals of the contactor/relay serve as second input conditions of automatic test criteria to be used for automatic judgment;
step nine, the automatic test system judges according to the input first input condition, the second input condition and the inverter fault protection logic list: if the test result meets the criterion condition, the automatic test system judges Pass, otherwise, the test result is Fail, and finally, an automatic test report is output.
2. The traction inverter control unit fault protection logic automated test method of claim 1, wherein the traction inverter system comprises a dc bus, an inverter, a motor, and a contactor/relay model.
3. The traction inverter control unit fault protection logic automated test method of claim 2, wherein the fault tree comprises a dc bus link fault, an inverter link fault, a motor link fault, and a contactor/relay fault; the direct current bus link faults comprise intermediate direct current side overvoltage faults, intermediate direct current side undervoltage faults, intermediate direct current loop short-circuit faults and intermediate direct current ground faults, and the intermediate direct current ground faults comprise intermediate direct current positive pole ground faults and intermediate direct current negative pole ground faults; the inverter link faults comprise an inversion U-phase driving fault, an inversion V-phase driving fault, a W-phase driving fault, an inversion output overcurrent fault and an inversion side grounding fault; the motor link faults comprise a motor phase loss fault, a motor non-working fault, a motor over-temperature fault and a motor over-speed fault; contactor/relay faults include a contactor/relay stuck-open fault and a contactor/relay stuck-open fault.
4. The automatic test method for the fault protection logic of the traction inverter control unit according to any one of claims 1 to 3, characterized in that the step of building a model by using an FPGA language in Matlab software.
5. The method for automatically testing the fault protection logic of the traction inverter control unit according to claim 4, wherein the step three comprises two parts:
1) compiling and downloading of simulation models: after the simulation model is built and off-line debugged, the simulation model is configured and compiled on the upper computer by using Higale code generation and compilation control software HiGale-Target to generate an executable file, and the executable file is downloaded into a board card of the simulation machine;
2) on the upper computer, a setting interface is integrated in a Simulink environment, and control and parameter monitoring of a simulation model are realized by configuring relevant parameters of a Simulink code generation tool Simulink code and cross-linking the control and monitoring interface matched with a simulation machine.
6. The method for automatically testing the fault protection logic of the control unit of the traction inverter according to claim 5, wherein in the first step, after a semi-physical simulation model of a main circuit of the traction inverter system is built, off-line debugging is performed, the second step is performed only after the off-line debugging is passed, and otherwise, the first step is returned to build the model again.
7. The automatic test method for the fault protection logic of the traction inverter control unit according to claim 6, wherein in the second step, after a fault model is built and a fault trigger condition is set, off-line debugging is performed, the third step is performed only after the off-line debugging is passed, and otherwise, the third step is performed again.
8. The automatic test method for the fault protection logic of the traction inverter control unit according to claim 7, wherein the fourth step further comprises downloading the debugged simulation model into a simulator card for semi-physical online joint debugging test with the traction inverter control unit TCU, and the fifth step is not performed until the online joint debugging test is passed.
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