CN118330363A

CN118330363A - Universal frequency converter testing system and method

Info

Publication number: CN118330363A
Application number: CN202410503875.7A
Authority: CN
Inventors: 王炜; 曹振涛; 栗晓江
Original assignee: Shenzhen Easydrive Electric Co ltd
Current assignee: Shenzhen Easydrive Electric Co ltd
Filing date: 2024-04-25
Publication date: 2024-07-12

Abstract

The invention relates to the field of frequency converter-based testing systems, in particular to a universal frequency converter testing system and method, comprising the following steps: the load simulator module is used for simulating various power supply conditions and load types; the measuring module is used for recording parameters such as voltage, current, frequency, power and the like in the operation process of the frequency converter; the control and data acquisition module comprises a central control unit and data acquisition hardware and is used for controlling the test process and collecting data; the software platform is used for configuring test parameters, executing test programs, collecting and analyzing data and generating reports; the output end of the load simulator module is connected with the input end of the frequency converter and is used for simulating the power supply condition and the load type and directly influencing the working environment of the frequency converter; the input end of the measuring module is connected with the output end of the frequency converter and is used for recording parameters such as voltage, current, frequency, power and the like in the operation process of the frequency converter in real time; the output end of the measuring module is connected with the input end of the control and data acquisition module to provide test data.

Description

Universal frequency converter testing system and method

Technical Field

The invention provides a universal frequency converter testing system and method, and belongs to the field of frequency converter testing systems.

Background

The frequency converter test system is a device and software system that is specifically used to detect and evaluate the performance of a frequency converter (Frequency Converter or Variable Frequency Drive, VFD). A frequency converter is a power electronic device that can vary the frequency and voltage of a power source to control the operating speed and torque of an Alternating Current (AC) motor. Frequency converters are widely used in industrial and commercial applications, such as regulating speed in pumps, fans, conveyor belts, etc.;

However, the prior art transducer testing system has the following disadvantages:

the prior art is not accurate enough in simulating actual power supply conditions and load types, resulting in a difference between the test environment and the actual operating environment. In addition, the prior art has limitations in data recording and processing, and cannot accurately capture key parameters or identify small changes in data, thereby affecting the accuracy and reliability of test results.

Existing frequency converter test systems lack flexibility in handling different test conditions and frequency converter types. For example, the system requires manual adjustment for different power supply specifications or load requirements, which is not only inefficient, but also prone to error. Also, existing systems are not effective against unexpected situations or parameter changes that occur during testing.

In some existing systems, there is a lack of efficient coordination and linkage between the various test modules (e.g., load simulator, measurement module, and control module). This means that when the parameters or conditions of one module change, the other module cannot respond or adjust in real time, resulting in a inconsistent and inefficient test procedure.

Disclosure of Invention

The invention provides a universal frequency converter testing system and method, and the adopted technical scheme is as follows:

A universal frequency converter test system, wherein the dynamic parameter adjustment module specifically comprises an algorithm for adjusting control parameters Kp and Km based on historical data and instant feedback. The algorithm uses linear regression analysis to predict optimal parameter settings, automatically adjusting parameters to accommodate variations in test conditions based on real-time changes in transducer performance.

The real-time monitoring module is responsible for collecting and analyzing data acquired from the frequency converter and the load simulator, automatically adjusting the testing environment through comparison with a preset threshold value, and ensuring the accuracy and reliability of testing. The module utilizes a specially designed feedback system to adjust the linkage strategy in real time, optimizes the cooperative work among the modules, and solves the problem of asynchronous response among the modules in the prior art.

The algorithm optimization module automatically identifies and adjusts key parameters in the test process through advanced data processing technology such as machine learning and pattern recognition, and improves the accuracy and response speed of the load simulation and test process. The module implements a self-adaptive algorithm, and adjusts the simulation load and the test conditions according to the real-time test data so as to adapt to the continuously-changing test requirements.

Further comprises:

the load simulator module is used for simulating various power supply conditions and load types;

the measuring module is used for recording parameters such as voltage, current, frequency, power and the like in the operation process of the frequency converter;

The control and data acquisition module comprises a central control unit and data acquisition hardware and is used for controlling the test process and collecting data;

the software platform is used for configuring test parameters, executing test programs, collecting and analyzing data and generating reports;

the output end of the load simulator module is connected with the input end of the frequency converter and is used for simulating power supply conditions and load types and directly influencing the working environment of the frequency converter;

The input end of the measuring module is connected with the output end of the frequency converter and is used for recording parameters such as voltage, current, frequency, power and the like in the operation process of the frequency converter in real time;

the output end of the measuring module is connected with the input end of the control and data acquisition module to provide test data;

the output end of the data acquisition module provides data and control signals for the software platform;

The user sets test parameters through the software platform, executes a test program and receives a test result, and the output end of the software platform sends a user instruction to the load simulator module;

The system provides a comprehensive test solution by integrating a load simulator module, a measurement module, a control and data acquisition module, and a software platform. The load simulator module can simulate various power supply conditions and provide diversified test environments for the frequency converter. The measuring module accurately records key parameters such as voltage, current and the like, and ensures the accuracy of data. The control and data acquisition module coordinates the whole test flow, and improves the test efficiency. The software platform provides a user-friendly interface, and is convenient for test configuration and data analysis. Overall, this system promotes the accuracy, efficiency and flexibility of the frequency converter test.

Preferably, the load simulator module comprises a load simulation optimization algorithm, the load simulation algorithm being as follows:

determining required power supply conditions and load types according to the input test parameters;

Calculating theoretical performance indexes of the frequency converter under the conditions;

According to the performance index, automatically adjusting the setting of the simulator to ensure the accuracy of the test conditions;

in the test process, the output of the simulator is monitored and regulated in real time so as to maintain a stable test environment;

The load simulation optimization algorithm ensures the accuracy and consistency of test conditions through intelligent calculation and automatic adjustment of simulator settings. The algorithm calculates theoretical performance indexes according to the input test parameters, and automatically adjusts the simulator according to the theoretical performance indexes, so that stable test environment is ensured to be maintained in the test process. The method improves the reliability of the test, so that the test result is closer to the performance of the frequency converter in actual use.

Preferably, the performance index is calculated by a theoretical performance formula, the theoretical performance formula comprising:

；

Wherein, Is the theoretical power of the frequency converter under specific power supply and load conditions,Is the input voltage of the power supply,Is the input current which is fed in from the current source,The theoretical performance formula is used for calculating the theoretical performance of the frequency converter under specific conditions and providing a basis for the adjustment of the simulator;

The input voltage, current and power factor angle are considered, so that the load simulator can adjust the output according to accurate theoretical values, thereby providing a test environment which is closer to actual working conditions. Such a calculation method improves the scientificity and practicality of the test.

Preferably, the measurement module comprises a measurement optimization algorithm, the measurement optimization algorithm being as follows:

before the test starts, the measuring equipment is automatically calibrated, so that the accuracy of data is ensured;

During the test, analyzing the collected data in real time to identify any fluctuations;

the measurement parameters are adjusted to cope with any emergency situation in the test, and the continuity and the accuracy of the data are ensured;

After the test is finished, carrying out preliminary analysis on the data to provide key performance indexes;

the measurement optimization algorithm ensures the accuracy and continuity of the data by automatically calibrating the measurement device and analyzing the test data in real time before the test begins. The method can timely identify any abnormal fluctuation in the data and correspondingly adjust the measurement parameters so as to adapt to the emergency in the test.

Preferably, the fluctuation is embodied by a fluctuation value calculated by a fluctuation value formula including:

；

Wherein, AndIndicating the extent of voltage and current fluctuation during the test respectively,AndIs at the firstThe voltage and current readings of the individual test points,AndIs the average value of the voltage and the current,The total number of the test points is the total number of the test points, and the fluctuation value formula is used for evaluating the stability of the voltage and the current in the test process and ensuring the accuracy and the reliability of the measured data;

by calculating the deviation of the voltage and current readings from their average values, these formulas help identify potential problems during testing, such as power instability or equipment failure. This approach enhances the monitoring capability of the test procedure.

Preferably, the synchronous consistency of power supply simulation and data measurement is achieved through a linkage load simulation optimization algorithm and a measurement optimization algorithm, and the method specifically comprises the following steps:

when the load simulation optimization algorithm adjusts the power supply and the load simulator, key parameter change information is transmitted to the measurement optimization algorithm in real time;

The measurement optimization algorithm dynamically adjusts the calibration and measurement parameters of the measurement module according to the received information;

The linkage mechanism enables the load simulation optimization algorithm and the measurement optimization algorithm to work synchronously, and when the simulator is set and adjusted, the measurement module correspondingly adjusts parameters of the simulator. The synchronization ensures the consistency between the test environment and the data acquisition, and improves the accurate matching of the power supply simulation and the data measurement in the test process. The cooperative working mode remarkably improves the overall efficiency and accuracy of the test.

Preferably, the measurement module adjustment value is calculated by a consistency formula comprising:

ΔP=K_p×(P_s−P)；

ΔM=K_m×ΔP

Wherein Δp represents the difference between the actual power and the theoretical power, P _s is the actual measured power, P is the theoretical power calculated by the load simulation optimization algorithm, K _p is the scaling factor adjusted by the power supply and the load simulator, Δm represents the adjustment value of the measurement module, and K _m is the scaling factor adjusted by the measurement module;

adjusting the simulator and the measurement parameters through a consistency formula to maintain the accuracy and consistency of the test;

The formula enables the testing system to flexibly respond to the change of the actual testing condition by calculating the difference value between the actual power and the theoretical power and adjusting the parameters of the measuring module based on the difference value. The adjustment ensures that the test conditions are always closely corresponding to the actual running state of the frequency converter, thereby improving the effectiveness and applicability of the test;

During the test, output parameters of the frequency converter, such as current, voltage and frequency, and corresponding load conditions are monitored and recorded in real time.

The current test error is calculated using the collected data based on a preset performance criteria. The test error is the difference between the actual output and the expected output for evaluating the effect of the current parameter setting.

The values of Kp and Km are adjusted according to the test error. The tuning process uses a gradient descent method with the aim of minimizing test errors. Specifically, if the test error increases, kp and Km are reduced; if the test error decreases, kp and Km are increased.

After each test, the values of Kp and Km are adjusted according to feedback and new parameter values are applied in the next test. This process is iterative and continues until a minimum test error or other stopping condition is reached.

The linkage strategy refers to a strategy of how the test modules (such as the load simulator, the measurement module and the control module) cooperate to achieve optimal test performance. The automatic adjustment linkage strategy comprises the following steps:

And monitoring the state and output of each module in real time. This includes receiving performance metrics and status reports from each module.

And evaluating the effectiveness of the existing linkage strategy according to the current module output and the overall system performance. A specially designed evaluation function is used to quantify the effect of the linkage strategy.

If the current strategy fails to achieve the desired effect, the system will automatically attempt a new linkage strategy. Policy optimization is based on machine learning algorithms, such as reinforcement learning, which discover the most efficient policy by trial and error.

After the optimal policy is selected, the policy is automatically implemented among the modules. This involves adjusting the manner of communication, the frequency of data sharing, or the order of operations between the modules.

Preferably, it comprises:

Dynamically adjusting the values of K _p and K _m according to the historical test data and the feedback of the current test;

Optimizing response speed and accuracy of a load simulation optimization algorithm and a test optimization algorithm so as to adapt to different test conditions and types of frequency converters;

Monitoring and analyzing the testing process in real time, and automatically adjusting the linkage strategy to improve the overall testing efficiency and reliability;

The load simulation optimization algorithm aims to improve the accuracy and adaptability of the simulated load, so that the load simulation optimization algorithm can accurately reflect the behavior of the frequency converter under the actual operation condition. The objective of the optimization is to reduce the difference between the simulated load and the actual load and to increase the speed of the algorithm adjustment under new load conditions, including:

an empirical statistical model based on laws of physics is selected.

The model parameters are automatically adjusted to best match the historical load data using data driven methods such as genetic algorithms, particle Swarm Optimization (PSO), or other global optimization techniques.

The model is cross-validated using the historical dataset to evaluate its performance on unknown data.

In practical testing algorithms are implemented to dynamically adjust the simulation parameters based on real-time feedback, using, for example, adaptive filtering techniques to ensure fast response to changing load conditions.

And calculating errors between the simulated load and the actually measured load, and analyzing the performances of the algorithm under different conditions.

The time required for adjusting the simulation parameters is measured, ensuring that the algorithm meets the requirement of quick response.

The time required by the algorithm to adjust to the optimal parameters and the time to reach the stable state are taken as performance indexes.

Various test conditions are simulated in the control environment, and the speed of the algorithm response change is recorded.

A test optimization algorithm is implemented in a load simulation system, and the time from an initial state to a set performance index is monitored by using a high-precision timing tool.

Experiments were repeated under different test scenarios to ensure consistency and reliability of results.

Statistical analysis is performed on the collected data, including average response time, standard deviation, etc., to evaluate the overall response speed of the algorithm.

And comparing the test result with an industry standard or an expected target to determine whether the algorithm meets the design requirement.

The values of K _p and K _m are dynamically adjusted based on historical test data and feedback from the current test. The self-adaptive adjustment mechanism enables the system to flexibly adapt to different testing conditions and types of frequency converters, and optimizes response speed and accuracy of a load simulation optimization algorithm and a measurement optimization algorithm. Through real-time monitoring and analysis of the test process, the system automatically adjusts the linkage strategy, thereby improving the overall test efficiency and reliability. The dynamic adjustment mechanism not only improves the intelligence of the system, but also ensures that high-quality test results can be obtained under various conditions.

A universal frequency converter testing method uses the universal frequency converter testing system.

The invention has the following beneficial effects:

1. Through a theoretical performance formula and a fluctuation value formula, the system can accurately simulate actual power supply conditions and load types, and accurately record key parameters such as voltage, current and the like. The application of these formulas ensures high accuracy and reliability of test conditions and results, making the test data closer to the actual operating state of the frequency converter.

2. The self-adaptive adjustment mechanism in the system adjusts the simulator and the measurement parameters according to a consistency formula, for example, so that the test process can flexibly adapt to different test conditions and types of frequency converters. This adaptive adjustment not only increases the flexibility of the test, but also enhances the system's ability to cope with various uncertainties and variations.

3. By means of the organic linkage of the load simulation optimization algorithm and the measurement optimization algorithm, the system can transmit key parameter change information to the measurement module in real time when the simulator is set and adjusted, and the measurement module can also dynamically adjust the calibration and measurement parameters of the measurement module to respond to the changes. The close cooperation and linkage among the modules greatly improve the efficiency and consistency of the whole test flow, ensure the close connection of the work of each stage and realize the high efficiency of cooperation.

Drawings

FIG. 1 is a block diagram of a universal converter testing system.

Detailed Description

The preferred embodiments of the present invention will be described below with reference to the accompanying drawings, it being understood that the preferred embodiments described herein are for illustration and explanation of the present invention only, and are not intended to limit the present invention.

1. Example 1:

A universal converter testing system comprising:

Specifically, the load simulator module includes a load simulation optimization algorithm, which is as follows:

Specifically, the performance index is calculated by a theoretical performance formula, which includes:

；

Specifically, the measurement module includes a measurement optimization algorithm that is as follows:

Specifically, the fluctuation is embodied by a fluctuation value calculated by a fluctuation value formula including:

；

Specifically, the synchronous consistency of power supply simulation and data measurement is achieved through a linkage load simulation optimization algorithm and a measurement optimization algorithm, and the method specifically comprises the following steps:

Specifically, the measurement module adjustment value is calculated by a consistency formula comprising:

ΔP=K_p×(P_s−P)；

ΔM=K_m×ΔP

the formula enables the testing system to flexibly respond to the change of the actual testing condition by calculating the difference value between the actual power and the theoretical power and adjusting the parameters of the measuring module based on the difference value. The adjustment ensures that the test conditions are always closely corresponding to the actual running state of the frequency converter, thereby improving the effectiveness and applicability of the test.

Specifically, the method comprises the following steps:

The beneficial effects of the embodiment are as follows:

2. Example 2:

a specific embodiment will be provided below and explain how each calculated value actually acts on a real world universal converter test system.

It is assumed that a specific type of frequency converter is tested, which has an input voltage of 380V, an input current of 10A and a power factor of 0.8 under ideal conditions. The test is performed using a universal transducer test system.

Setting a power supply and load simulator module:

the power supply and load simulator module simulates corresponding power supply conditions based on the entered test parameters (380 v,10a, 0.8).

The measurement module records data:

during the test, the measuring module records the actual output voltage and current of the frequency converter.

Theoretical power is calculated using equation 1 of algorithm 1:

；

the control and data acquisition module analyzes the data:

Let us assume that during the test, the actual measured power is P _s =5200W.

Adjusting the simulator and the measurement parameters:

calculating a power difference value: Δp=5265w-5200 w=65w;

Assuming K _p =0.1 and K _m =0.05, there are: Δm=0.05×65w=3.25W;

The self-adaptive adjustment mechanism optimizes the linkage strategy:

Based on feedback during the test, the values of K _p and K _m are adaptively adjusted to more accurately match the actual test conditions.

And according to the delta P and the delta M, the output of the power supply and the load simulator and the parameters of the measuring module are automatically adjusted to ensure that the test conditions are closer to the actual working environment.

After the test is completed, data is collected and analyzed to generate a test report.

The simulator is adjusted to more accurately reflect the actual operating conditions. If ΔP is positive, indicating that the actual power is lower than the theoretical power, the output power of the simulator needs to be increased. Conversely, if negative, the output power needs to be reduced.

The adjustment process can be implemented by changing the voltage or current output by the simulator, depending on the operating characteristics and test requirements of the frequency converter.

ΔM is used to adjust parameters of the measurement module. This involves changing the sensitivity, sampling frequency, or other relevant settings of the measurement module to more accurately capture test data.

If ΔM indicates that finer measurements are needed, the sampling frequency may be increased or the data processing algorithm adjusted to analyze the collected data more carefully.

These adjustments may be performed automatically by a control and data acquisition module that sends adjustment instructions to the corresponding modules based on the results of the calculations of Δp and Δm.

The self-adaptive adjustment mechanism in the test system monitors the adjusted effect and further optimizes the values of K _p and K _m according to real-time data feedback, so that the adjustment process is more accurate and efficient.

Claims

1.A universal converter testing system, comprising:

the load simulator module is used for simulating power supply conditions and load types;

the measuring module is used for recording parameters of voltage, current, frequency and power in the operation process of the frequency converter;

The output end of the load simulator module is connected with the input end of the frequency converter, so that the working environment of the frequency converter is influenced;

The input end of the measuring module is connected with the output of the frequency converter;

And the user sets the test parameters through the software platform, executes the test program and receives the test result, and the output end of the software platform sends a user instruction to the load simulator module.

2. The universal converter testing system of claim 1, wherein the load simulator module comprises a load simulation optimization algorithm that is as follows:

During the test, the output of the simulator is monitored and adjusted in real time to maintain a stable test environment.

3. The universal converter testing system of claim 2, wherein the performance index is calculated by a theoretical performance formula comprising:

；

Wherein, Is the theoretical power of the frequency converter under specific power supply and load conditions,Is the input voltage of the power supply,Is the input current which is fed in from the current source,The theoretical performance formula is used for calculating the theoretical performance of the frequency converter under specific conditions and provides a basis for adjustment of the simulator.

4. A universal converter testing system according to claim 3, wherein the measurement module comprises a measurement optimization algorithm, the measurement optimization algorithm being as follows:

After the test is finished, the data are subjected to preliminary analysis, and key performance indexes are provided.

5. The universal converter testing system of claim 4, wherein the ripple is embodied by a ripple value calculated by a ripple value formula comprising:

；

Wherein, AndIndicating the extent of voltage and current fluctuation during the test respectively,AndIs at the firstThe voltage and current readings of the individual test points,AndIs the average value of the voltage and the current,The fluctuation value formula is used for evaluating the stability of voltage and current in the test process and ensuring the accuracy and reliability of measured data.

6. The universal converter testing system of claim 5, wherein the synchronous consistency of power supply simulation and data measurement is achieved by a coordinated load simulation optimization algorithm and a measurement optimization algorithm, comprising:

And the measurement optimization algorithm dynamically adjusts the calibration and measurement parameters of the measurement module according to the received information.

7. The universal converter testing system of claim 6, wherein the measurement module adjustment value is calculated by a consistency formula comprising:

ΔP=K_p×(P_s−P)；

ΔM=K_m×ΔP；

And adjusting the simulator and the measurement parameters through a consistency formula so as to maintain the accuracy and consistency of the test.

8. The universal converter testing system of claim 7, comprising:

and the testing process is monitored and analyzed in real time, and the linkage strategy is automatically adjusted so as to improve the overall testing efficiency and reliability.

9. A universal frequency converter testing method, characterized in that a universal frequency converter testing system according to any of claims 1-8 is used.