Load system

Abstract

The invention discloses a load system, and belongs to the field of generator set testing, the load system comprises a box body, a control system, a resistive load, an inductive load, a transformer and a switch cabinet, the control system, the resistive load and the inductive load are all arranged in the box body; the control system is used for communicating with each component and controlling the operation of each component; the number of the resistive loads is multiple, and each resistive load is used for converting electric energy into heat energy and carrying out continuous discharge test on equipment to be tested; the inductive load is used for adjusting the inductive load, is matched with the resistive load, adjusts the load power factor, and simulates the actual working state of the to-be-tested device. The transformer is used for providing power for a load system; the switch cabinet is used for controlling on and off of the load system, measuring data of equipment to be tested, protecting normal operation of the system and distributing electric energy. All the components are matched, the actual working load of the to-be-tested equipment can be effectively simulated, and the performance and stability of the to-be-tested equipment are evaluated.

Description

Technical Field

[0001] The invention belongs to the field of generator set testing, and in particular relates to a load system. Background Art

[0002] The load system can be used to simulate the actual workload of the device under test and evaluate the performance and stability of the device under test. The existing load system is unstable and cannot effectively evaluate the device under test. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a load system in view of the above-mentioned deficiencies in the prior art, in which various components cooperate to effectively simulate the actual workload of the device under test and evaluate the performance and stability of the device under test.

[0004] The technical solution adopted by the present invention is: a load system, including a box, a control system, a resistive load, an inductive load, a transformer and a switch cabinet, wherein the control system, the resistive load and the inductive load are all arranged in the box; The control system is used to communicate with each component and control the operation of each component; There are several resistive loads, each of which is used to convert electrical energy into thermal energy to perform a continuous discharge test on the device under test; At least two heat dissipation fans are provided on the side of each resistive load, and the two heat dissipation fans are used for forced air cooling to dissipate heat generated by the resistive load conversion and maintain the temperature of the resistive load; The inductive load is used to adjust the inductive load, cooperate with the resistive load, adjust the load power factor, and simulate the actual working state of the device under test; The transformer is used to provide power to the load system; The switch cabinet is used to control the opening and closing of the load system, measure the data of the equipment to be tested, protect the normal operation of the system and distribute electric energy.

[0005] In one embodiment, the control system includes a programmable logic controller, a contactor, an instrument and a human-computer interface; The programmable logic controller is connected to the contactor, the instrument and the human-machine interface respectively, and is used to communicate with each component, output control signals and control the operation of each component; The contactor is connected to the programmable logic controller to control load switching and the start and stop of the cooling fan; The instrument is connected to a programmable logic controller and is used to display the collected data; The human-computer interaction interface is connected to a programmable logic controller for human-computer interaction.

[0006] In one embodiment, each of the resistive loads includes a plurality of load modules, each of the load modules includes a shell, a plurality of resistor tubes disposed in the shell, and an output connecting plate disposed outside the shell, and each of the resistor tubes is connected to the output connecting plate.

[0007] In one embodiment, each of the resistor tubes includes a hollow tube body, a resistance wire is arranged inside the tube body, and a filling material is filled between the resistance wire and the tube body. Joints are arranged at both ends of the resistance wire, and both joints are connected to the output connecting plate.

[0008] In one of the embodiments, a plurality of heat dissipation fins are disposed on the outer side of the tube body.

[0009] In one of the embodiments, each of the heat dissipation fan outlets is provided with an air duct, and the air duct is provided with a plurality of water baffles.

[0010] In one of the embodiments, the air duct is arranged at an angle.

[0011] In one embodiment, the inductive load includes a plurality of reactors and a number of fuses that is the same as the number of the reactors, each of the reactors is connected to each of the fuses in pairs, and each of the fuses is also connected to a contactor and a plurality of load modules respectively.

[0012] In one embodiment, the switch cabinet includes a switch assembly, a circuit breaker, a collection assembly and a comprehensive protection device; The switch assembly is connected to the transformer and the programmable logic controller respectively, and is used to control the opening and closing of the load system; The circuit breaker is connected to the switch assembly and is used to cut off the circuit when a circuit fault occurs to protect the load system; The acquisition component is connected to the programmable logic controller and the instrument respectively, and is used to measure the data of the device to be tested and output it to the instrument; The comprehensive protection device is connected to a programmable logic controller and is used to protect the high voltage circuit.

[0013] In one embodiment, the acquisition component includes a current transformer and a voltage transformer; The current transformer is connected to the programmable logic controller and the instrument respectively, and is used to measure the current data of the device to be tested and output the measured current data to the instrument; The voltage transformer is connected to the programmable logic controller and the instrument respectively, and is used to measure the voltage data of the device to be tested and output the measured voltage data to the instrument.

[0014] The beneficial effect of the present invention is that the various components cooperate to effectively simulate the actual workload of the device under test and evaluate the performance and stability of the device under test. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a structural block diagram of the present invention; Figure 2 It is a schematic diagram of the structure of the present invention; Figure 3 This is a schematic diagram of the load module structure of the present invention; Figure 4 This is a schematic diagram of the connection between the resistor tube and the output connection board of the present invention; Figure 5 It is a schematic diagram of the structure of the resistor tube of the present invention.

[0016] In the figure: 1. box; 2. control system; 3. resistive load; 4. inductive load; 5. transformer; 6. switch cabinet; 7. cooling fan; 11. air duct; 12. water baffle; 21. programmable logic controller; 22. contactor; 23. instrument; 24. human-machine interface; 31. load module; 311. shell; 312. resistor tube; 313. output connection board; 3121. tube body; 3122. joint; 3123. cooling fin; 3124. resistance wire; 3125. filling material; 41. reactor; 42. fuse; 61. switch assembly; 62. circuit breaker; 63. acquisition assembly; 64. integrated protection device; 631. current transformer; 632. voltage transformer. DETAILED DESCRIPTION

[0017] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0018] like Figure 1-Figure 5 As shown, the present invention discloses a load system, including a box 1, a control system 2, a resistive load 3, an inductive load 4, a transformer 5 and a switch cabinet 6, wherein the control system 2, the resistive load 3 and the inductive load 4 are all arranged in the box 1; The control system 2 is used to communicate with each component and control the operation of each component; There are several resistive loads 3, and each of the resistive loads 3 is used to convert electrical energy into thermal energy to perform a continuous discharge test on the device under test; At least two heat dissipation fans 7 are provided on the side of each resistive load 3, and the two heat dissipation fans 7 are used for forced air cooling to dissipate heat converted by the resistive load 3 and maintain the temperature of the resistive load 3; The inductive load 4 is used to adjust the inductive load, cooperate with the resistive load 3, adjust the load power factor, and simulate the actual working state of the device under test; The transformer 5 is used to provide power to the load system; The switch cabinet 6 is used to control the opening and closing of the load system, measure the data of the equipment to be tested, protect the normal operation of the system and distribute electric energy.

[0019] In this embodiment, the control system 2 includes a programmable logic controller 21, a contactor 22, an instrument 23 and a human-machine interface 24; The programmable logic controller 21 is connected to the contactor 22, the instrument 23 and the human-machine interface 24 respectively, and is used to communicate with each component, output control signals and control the operation of each component; The contactor 22 is connected to the programmable logic controller 21 and is used to control the load switching and the start and stop of the cooling fan 7; The instrument 23 is connected to the programmable logic controller 21 and is used to display the collected data; The human-computer interaction interface 24 is connected to the programmable logic controller 21 for human-computer interaction.

[0020] In this embodiment, each of the resistive loads 3 includes several load modules 31, each of the load modules 31 includes a shell 311, several resistor tubes 312 arranged in the shell 311 and an output connecting plate 313 arranged on the outside of the shell 311, and each of the resistor tubes 312 is connected to the output connecting plate 313.

[0021] In this embodiment, each of the resistor tubes 312 includes a hollow tube body 3121, a resistance wire 3124 is provided inside the tube body 3121, a filling material 3125 is filled between the resistance wire 3124 and the tube body 3121, and joints 3122 are provided at both ends of the resistance wire 3124, and the two joints 3122 are connected to the output connecting plate 313.

[0022] In this embodiment, a plurality of heat dissipation fins 3123 are disposed on the outer side of the tube body 3121 .

[0023] In this embodiment, an air duct 11 is provided on the air outlet of each of the heat dissipation fans 7 , and a plurality of water baffles 12 are provided on the air duct 11 .

[0024] In this embodiment, the air duct 11 is arranged at an angle.

[0025] In this embodiment, the inductive load 4 includes a plurality of reactors 41 and fuses 42 of the same number as the reactors 41 , each reactor 41 is connected to each fuse 42 in pairs, and each fuse 42 is also connected to a contactor 22 and a plurality of load modules 31 , respectively.

[0026] In this embodiment, the switch cabinet 6 includes a switch assembly 61, a circuit breaker 62, a collection assembly 63 and a comprehensive protection device 64; The switch assembly 61 is connected to the transformer 5 and the programmable logic controller 21 respectively, and is used to control the opening and closing of the load system; The circuit breaker 62 is connected to the switch assembly 61 and is used to cut off the circuit when a circuit fault occurs to protect the load system; The acquisition component 63 is connected to the programmable logic controller 21 and the instrument 23 respectively, and is used to measure the data of the device under test and output it to the instrument 23; The integrated protection device 64 is connected to the programmable logic controller 21 and is used to protect the high voltage circuit.

[0027] In this embodiment, the acquisition component 63 includes a current transformer 631 and a voltage transformer 632; The current transformer 631 is connected to the programmable logic controller 21 and the meter 23 respectively, and is used to measure the current data of the device under test and output the measured current data to the meter 23; The voltage transformer 632 is connected to the programmable logic controller 21 and the meter 23 respectively, and is used to measure the voltage data of the device under test and output the measured voltage data to the meter 23.

[0028] In this application, the outside of the box 1 is sprayed with special paint that is resistant to salt spray, acid and alkali, and seawater erosion, and the inside is sprayed with high-temperature resistant paint. The internal brackets for installing various components are hot-dip galvanized to ensure the service life of the box 1.

[0029] In the present application, the load module 31 is arranged by a guide rail and can be pulled out for independent maintenance and convenient replacement.

[0030] In the present application, an air inlet is provided at the position corresponding to each resistive load 3 and the heat dissipation fan 7 on the box body 1, and an air outlet is provided at the top. In order to improve the protection level and adjust and optimize the inlet and outlet angles to avoid the formation of a heat island effect, the inlet and outlet are designed with shutters, the air inlet is equipped with sound insulation cotton to reduce the fan noise, and a protective net is added to prevent foreign objects from intruding. The air outlet has adjusted its angle to avoid rainwater intrusion. At the same time, the top outlet can avoid the formation of a heat island effect and avoid direct side discharge of high-temperature air. Two independent air ducts 11 are provided for the heat dissipation fan 7 corresponding to each resistance, and a water retaining plate 12 is added to the air duct 11 to prevent rainwater from flowing in.

[0031] In this application, in order to achieve better use effect, the resistor tube 312 adopts the following design: (1) The material of resistance wire 3124 is nickel-chromium alloy with high temperature resistance (maximum working temperature is 1300℃), stable electrical performance and small temperature drift coefficient.

[0032] (2) The materials of the various components of the resistor tube 312 are strictly controlled in accordance with relevant regulations. The tube body 3121 is made of stainless steel 304 with high ductility and oxidation resistance. The filling material 3125 is export-grade electrical crystalline magnesium oxide powder (Sg-9), and the implementation standard is JBY-TE4088-199. The density of magnesium sand during the manufacturing process is 3.0g / cm3±0.2. The wiring screws and fixing screw columns are made of corrosion-resistant and high-temperature resistant stainless steel 321 (1Cr18Ni9Ti).

[0033] (3) The heat dissipation fin 3123 is made of stainless steel with a height of 7 mm ± 2 and a thickness of 0.4 mm ± 0.2. The winding interval of the heat dissipation fin 3123 is less than or equal to 3 mm ± 0.2.

[0034] (4) The withstand voltage of a single resistor tube 312 is DC3000V or AC1500V, 50Hz, and it will not break down for 1 minute.

[0035] (5) When the resistor tube 312 is in normal working condition, the average temperature of the heat sink fin 3123 is ≤300°C, and the maximum temperature is 320°C, which is nearly 5 times the maximum temperature of the resistor 1300°C. This ensures that the resistor tube 312 can work continuously.

[0036] (6) When the power resistance reaches 300℃-400℃, the temperature drift is still ≤±2%, thus ensuring that the load resistance value will not fluctuate greatly under high temperature conditions, and a stable power value can be loaded at any temperature.

[0037] (7) Regardless of cold or hot state, the load error is ≤±3%.

[0038] In this application, the inductive load 4 is composed of several reactors 41, which are mainly used to adjust the inductive load during the load test. In combination with the resistive load 3, the load power factor can be adjusted to simulate the actual working state of the generator set. The composition structure of the reactor 41 is as follows: the coil of the reactor 41 is a silk-coated, non-woven coated wire, which can operate stably for a long time under the rated load. It has the characteristics of moisture-proof, salt spray-proof, mildew-proof, acid-resistant, and aging-resistant. A three-phase iron core reactor 41 is used, which is made of oxygen-free enameled wire wound, dipped in varnish and sealed at the end; the coil is made of pure copper, the iron core is made of Baosteel's high-quality cold-rolled oriented silicon steel sheet, and the air gap is separated by epoxy laminated glass cloth board to ensure that the reactor air gap does not change during operation; the coil and the iron core of the reactor 41 are assembled into one, and then pre-baked → vacuum dipped in varnish → dried and cured → end-sealed, and H-class insulating varnish is used to firmly combine the coil and the iron core of the reactor 41; the fasteners of the reactor 41 are made of non-magnetic materials to ensure that the reactor 41 has a high quality factor and a low temperature rise (the maximum temperature rise is 80K under overload conditions), ensuring a good operating effect; insulation and anti-corrosion treatment is adopted, which has the characteristics of low loss, high efficiency, low temperature rise, and long-term stable operation under rated load box. Reactor 41 is installed outdoors and uses natural air cooling. It has the characteristics of no noise (less than 60 decibels at rated voltage), no pollution, good heat resistance (Class B, temperature rise ≤80k under overload), no need for daily maintenance, and long service life. The iron core and metal parts of reactor 41 have an anti-corrosion protective layer and are reliably grounded. The grounding devices are also equipped with anti-rust coating.

[0039] In this application, Siemens brand 200SMART series programmable logic controller 21 is selected as the logic controller to control the load system operation logic and realize the control function. This series of programmable logic controller 21 has rich communication interfaces, rich communication resources, reliable performance, powerful functions, and meets the design requirements. The S7-200SMART SR / ST CPU module body integrates 1 Ethernet interface and 1 RS485 interface. By expanding the CM01 signal board or EM DP01 module, the number of communication ports can be increased to 4 at most, which can meet the needs of small automation equipment to communicate with touch screens, inverters and other third-party devices. The S7-200 SMART CPU module can fully meet the various needs of different industries, different customers, and different equipment.

[0040] In the present application, the contactor 22 uses a Schneider brand three-pole AC contactor 22, which is mainly used to control load switching and the start and stop of the cooling fan 7. This series of contactors 22 has a low failure rate, a long service life, stable and reliable performance, and a large current range.

[0041] In this application, the instrument 23 uses the Qingzhi instrument 233433C series, a high-precision liquid crystal display instrument 23. The instrument 23 has high precision (0.2 level), reliable performance, and meets the design requirements.

[0042] In the present application, the transformer 5 is used in conjunction with the load system, and each load is equipped with two transformers 5. The insulation grade of the transformer 5 reaches Class F, the temperature resistance is 155C, the actual operating temperature rise is low, the overload capacity is strong, and it can be operated at 120% overload for a long time under the condition of self-cooling, and can be operated at 150% overload under the condition of forced air cooling. At the same time, the transformer 5 has reliable performance, safe operation, convenient maintenance, high overall mechanical strength, strong short-circuit tolerance, good impact overvoltage tolerance, and good moisture resistance.

[0043] The above-mentioned embodiments only express the specific implementation of the present invention, and the description thereof is relatively specific and detailed, but it cannot be understood as limiting the scope of the present invention. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention.

Claims

1. A load system, characterized in that: It comprises a box (1), a control system (2), a resistive load (3), an inductive load (4), a transformer (5) and a switch cabinet (6), wherein the control system (2), the resistive load (3) and the inductive load (4) are all arranged in the box (1); The control system (2) is used to communicate with each component and control the operation of each component; There are a plurality of resistive loads (3), and each of the resistive loads (3) is used to convert electrical energy into thermal energy to perform a continuous discharge test on the device under test; At least two heat dissipation fans (7) are provided on the side of each resistive load (3), and the two heat dissipation fans (7) are used to perform forced air cooling to dissipate heat, discharge heat converted by the resistive load (3), and maintain the temperature of the resistive load (3); The inductive load (4) is used to adjust the inductive load, and cooperates with the resistive load (3) to adjust the load power factor and simulate the actual working state of the device to be tested; The transformer (5) is used to provide power to the load system; The switch cabinet (6) is used to control the opening and closing of the load system, measure the data of the equipment to be tested, protect the normal operation of the system and distribute electric energy.

2. A load system according to claim 1, characterized in that: The control system (2) comprises a programmable logic controller (21), a contactor (22), an instrument (23) and a human-machine interaction interface (24); The programmable logic controller (21) is respectively connected to the contactor (22), the instrument (23) and the human-machine interface (24) and is used to communicate with each component, output control signals and control the operation of each component; The contactor (22) is connected to the programmable logic controller (21) and is used to control load switching and the start and stop of the cooling fan (7); The instrument (23) is connected to the programmable logic controller (21) and is used to display the collected data; The human-machine interaction interface (24) is connected to the programmable logic controller (21) and is used for human-machine interaction.

3. A load system according to claim 1, characterized in that: Each of the resistive loads (3) comprises a plurality of load modules (31), each of the load modules (31) comprises a housing (311), a plurality of resistance tubes (312) arranged in the housing (311), and an output connection board (313) arranged outside the housing (311), and each of the resistance tubes (312) is connected to the output connection board (313).

4. A load system according to claim 3, characterized in that: Each of the resistance tubes (312) comprises a hollow tube body (3121), a resistance wire (3124) is arranged inside the tube body (3121), a filling material (3125) is filled between the resistance wire (3124) and the tube body (3121), and joints (3122) are arranged at both ends of the resistance wire (3124), and the two joints (3122) are connected to the output connection plate (313).

5. A load system according to claim 4, characterized in that: A plurality of heat dissipation fins (3123) are provided on the outside of the tube body (3121).

6. A load system according to claim 5, characterized in that: An air duct (11) is provided on the air outlet of each heat dissipation fan (7), and a plurality of water baffles (12) are provided on the air duct (11).

7. A load system according to claim 6, characterized in that: The air duct (11) is arranged at an angle.

8. A load system according to claim 2 or 7, characterized in that: The inductive load (4) comprises a plurality of reactors (41) and fuses (42) whose number is the same as that of the reactors (41); each of the reactors (41) is connected to each of the fuses (42) in pairs; and each of the fuses (42) is also respectively connected to a contactor (22) and a plurality of load modules (31).

9. A load system according to claim 8, characterized in that: The switch cabinet (6) comprises a switch assembly (61), a circuit breaker (62), a collection assembly (63) and a comprehensive protection device (64); The switch assembly (61) is connected to the transformer (5) and the programmable logic controller (21) respectively, and is used to control the opening and closing of the load system; The circuit breaker (62) is connected to the switch assembly (61) and is used to cut off the circuit when a circuit fault occurs, thereby protecting the load system; The acquisition component (63) is connected to the programmable logic controller (21) and the instrument (23) respectively, and is used to measure the data of the device to be tested and output it to the instrument (23); The comprehensive protection device (64) is connected to the programmable logic controller (21) and is used to protect the high-voltage circuit.

10. A load system according to claim 9, characterized in that: The acquisition component (63) comprises a current transformer (631) and a voltage transformer (632); The current transformer (631) is connected to the programmable logic controller (21) and the instrument (23) respectively, and is used to measure current data of the device to be tested and output the measured current data to the instrument (23); The voltage transformer (632) is connected to the programmable logic controller (21) and the meter (23) respectively, and is used to measure voltage data of the device to be tested and output the measured voltage data to the meter (23).

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