Engine loading power extraction multi-load integrated control system and method

Abstract

The application discloses an engine loading power extraction multi-load integrated control system and method, and belongs to the technical field of engine test control. The system comprises a host computer, a PLC control unit, a database and a field device layer. The field device layer comprises electronic load, hydraulic load, fuel load and air load branch. The host computer is used for mode selection, parameter setting, control instruction generation and state display; the PLC control unit is used for logical judgment, task allocation, interlocking protection and closed-loop correction; the database is used for operation data storage and management. For valve control load, the host computer generates a reference command current, and uses historical data and a prediction model to intelligently correct the initial current; the PLC combines field feedback to complete closed-loop regulation. The application integrates multiple loads into a unified control platform, realizes centralized monitoring, collaborative scheduling and unified data management, reduces the dependence on manual experience, and improves the load response speed, control accuracy and system integration.

Description

Technical Field

[0001] This invention belongs to the field of engine test control and industrial automation control technology, specifically involving an integrated control system and method for engine loading power extraction based on the collaboration of host computer and PLC. It is applicable to power extraction and collaborative control in engine high-altitude test, ground simulation test and multi-type load joint control scenarios. Background Technology

[0002] During engine testing and related ground simulation tests, it is typically necessary to control multiple loads, including electronic loads, hydraulic loads, fuel loads, and bleed air loads, to simulate power extraction, energy consumption, and auxiliary system operation under different engine flight conditions. Existing test and control systems usually need to simultaneously perform tasks such as parameter measurement and data acquisition, status monitoring and alarms, and process equipment control and adjustment. Moreover, with the increase in test objects, faster switching of operating conditions, and more complex data links, control systems have gradually evolved from single-device control to multi-level systems encompassing upper-level monitoring, controllers, actuators, and sensors.

[0003] Publicly available technologies indicate that engine testing and control scenarios generally involve data interaction between the upper-level layer, PLC control layer, acquisition layer, and execution layer. Furthermore, there are often problems such as unsmooth communication links, inconsistent protocols, and insufficient compatibility between devices from different levels and manufacturers. This makes system integration and collaborative scheduling in multi-object test control increasingly difficult.

[0004] In existing technologies, multiple types of loads often employ a distributed control architecture, where different load objects are configured with independent control units, independent operating interfaces, or independent parameter loops. While this approach can meet the basic start-up, shutdown, and regulation needs of a single object, it is prone to problems such as dispersed control entry points, inconsistent parameter configurations, fragmented status monitoring, separation of alarms and historical records, and difficulty in centralized management of interlocking logic when multiple loads operate in parallel, are jointly loaded, or frequently switch between test conditions. Conventional industrial HMI / SCADA and PLC systems typically support online data exchange, alarm display, operation screens, and data transmission. However, when the number of controlled objects in the system increases, communication links lengthen, and cross-level coordination is required, relying solely on traditional distributed monitoring methods often fails to balance communication efficiency, scalability flexibility, and control consistency. Especially in scenarios requiring unified distribution of control parameters, centralized feedback of operating status, and coordinated scheduling of multiple execution devices, existing solutions still have shortcomings in terms of platform integration and engineering adaptability.

[0005] On the other hand, in hydraulic loads, fuel loads, and bleed air loads, the control process typically relies on actuators such as proportional valves, regulating valves, pilot valves, or flow control valves to dynamically adjust pressure, flow rate, valve position, or related process quantities. Public information shows that these valve-controlled elements are widely used in automated electro-hydraulic or fluid control scenarios, and can achieve proportional flow rate, pressure, or opening adjustment based on electrical signals. Closed-loop control, position feedback, and onboard electronic control have become important means to improve adjustment accuracy and dynamic performance. However, if multiple types of valve-controlled loads lack a unified integrated control platform and only use local adjustment or manual tuning methods, then when target parameters change, operating conditions switch, or multiple loads operate in tandem, phenomena such as valve position adjustment lag, uncoordinated response, insufficient control accuracy, and scattered protection actions are likely to occur, thus affecting the stability, automation level, and subsequent expansion capabilities of the overall test system.

[0006] Therefore, it is necessary to propose an integrated control system and control method for multiple types of load objects. This system can achieve centralized monitoring, unified scheduling and interlocking protection through collaboration between the upper level and PLC, and establish an automatic closed-loop regulation mechanism for the internal actuators of each load to improve the system's integration, real-time performance, regulation capability and engineering application level. Summary of the Invention

[0007] The purpose of this invention is to provide an integrated control system and method for extracting engine load power across multiple loads, in order to solve the problems of independent loads, inconsistent control links, insufficient automatic adjustment capability of valve control actuators, and lack of unified interlock protection in existing systems, and to achieve unified scheduling, automatic control and status feedback of electronic loads, hydraulic loads, fuel loads and bleed air loads.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: an integrated control system for extracting engine loading power under multiple loads, comprising a host computer, a PLC control unit, a database, and a field device layer;

[0009] The host computer is used for selecting operating modes, configuring load combinations, setting target parameters, selecting operating conditions, generating control commands, displaying operating status, providing alarm prompts, and managing historical data.

[0010] The PLC control unit is used to receive control commands, mode information and target parameters issued by the host computer, and to perform logical judgment, task allocation, timing coordination, status acquisition, control output, interlock protection, closed-loop correction and fault response.

[0011] The database is used for unified storage, classification management, and traceability analysis of operational data, alarm information, operation records, and historical task information;

[0012] The field device layer includes electronic load branches, hydraulic load branches, fuel load branches, and bleed air load branches. Each branch establishes a signal interaction relationship with the PLC control unit to form a unified closed-loop control link between the host computer, PLC, and field devices.

[0013] Furthermore, the host computer and the PLC control unit communicate bidirectionally via industrial Ethernet, preferably using Modbus TCP communication. The host computer, acting as the master station, sends control parameters and reads status data from the PLC control unit. After receiving the operating mode, target setpoint, stage parameters, and load combination information sent by the host computer, the PLC parses the relevant instructions and converts them into corresponding analog, digital, or communication control signals according to the type of the controlled object, sending them to the field equipment layer. Simultaneously, the PLC control unit uploads the operating status of each branch, feedback parameters, alarm information, and fault status to the host computer for display, recording, and further processing.

[0014] Furthermore, the PLC control unit is internally equipped with an instruction parsing and pattern matching module, a task allocation and sequence control module, a synchronization coordination module, a data acquisition module, a closed-loop correction module, and a fault response module. Among them, the task allocation and sequence control module is used to organize the start-up, switching, holding, and exit processes of each load branch according to the current equipment status, allowable conditions, and interlocking constraints. The closed-loop correction module is used to correct the execution quantity in real time based on the field feedback.

[0015] Furthermore, the host computer includes a manual input control mode and a preset operating condition automatic control mode. In the manual input control mode, the operator directly inputs the target power, target pressure, target flow rate, target valve position, or other target control quantities, which are then processed by the host computer and sent to the PLC control unit for execution. In the preset operating condition automatic control mode, the operator pre-sets the target operating condition and its stage process in the PLC control unit. The host computer selects the operating condition number and sends a trigger command to the PLC control unit, which automatically executes the entire task process to achieve fully automatic control for the test process.

[0016] Furthermore, the hydraulic load branch includes an oil supply pump, an unloading unit, a throttle valve, a fixed flow unit, a proportional pressure regulating valve, a flow meter, a pressure relief valve, and a pressure gauge; the fuel load branch includes a pressure gauge, a flow meter, a power switch, a bypass regulating valve, and a main regulating valve; the bleed air load branch includes a regulating valve, a pilot valve, a pressure relief valve, and a pressure and flow detection unit; the electronic load branch is used to extract the electrical loading power according to the mode information and input current set by the host computer, and return voltage, current, power, and operating status information to the host computer.

[0017] Furthermore, for valve-controlled objects such as hydraulic load branches, fuel load branches, and bleed air load branches, the host computer is equipped with a reference command current generation module. The reference command current generation module first generates a basic initial command current based on the target operating condition, target flow rate, valve calibration relationship, and operating constraints. Then, it generates a predicted correction amount for the basic initial command current based on historical operating data, current operating condition information, target parameters, historical command current inputs, and historical feedback results to obtain the reference command current. The host computer sends the reference command current to the PLC control unit as an execution reference value. The PLC control unit or field equipment, combined with the field feedback, performs subsequent corrections to the execution amount through closed-loop control, thereby reducing the number of manual adjustments and shortening the time for relevant branches to enter the target operating condition.

[0018] Furthermore, the reference command current generation module is also equipped with a manual fine-tuning interface, which is used to manually increase or decrease the reference command current under special operating conditions, during the debugging stage, or when the prediction model has not converged; the prediction correction amount is output by the time series prediction model, and the input features of the time series prediction model are obtained by filtering the candidate feature set through a feature screening algorithm with feature importance evaluation capability.

[0019] Furthermore, the database is associated with the host computer and is used to classify and store data according to operating mode, load type, time, operating condition stage and alarm category. The data stored in the database includes at least target set value, control output value, real-time feedback value, alarm information, fault record, operation record and date information. The historical data in the database is used for the training, updating and verification of the command current generation module.

[0020] This invention also provides a multi-load integrated control method for extracting engine loading power based on the above system, comprising:

[0021] Select the single-load operation mode or multi-load combination operation mode in the host computer according to the target test scenario, and input the target power, target pressure, target flow rate, target valve position or preset operating condition number;

[0022] The host computer generates control tasks; for valve-controlled objects such as hydraulic load branches, fuel load branches, and bleed air load branches, reference command currents are further generated.

[0023] The control task, target parameters, and reference command current are sent to the PLC control unit.

[0024] The PLC control unit judges and assigns tasks based on the current status, permissible conditions, and interlocking rules, and drives the corresponding branches to execute in a set sequence;

[0025] During operation, the status and feedback quantities of each branch are collected in real time, and closed-loop correction is performed based on the deviation between the target value and the feedback value.

[0026] Write operational information, alarm information, and historical task information into the database.

[0027] Furthermore, the generation of the reference command current includes:

[0028] Based on the target power, target pressure setpoint and / or target flow rate, and combined with the valve flow model or empirical calibration relationship, a basic initial command current is generated;

[0029] Based on historical operating data, current operating condition information, target parameters, historical command current and historical feedback data, a predicted correction amount is generated, and the predicted correction amount is superimposed on the basic initial command current to obtain the reference command current.

[0030] In special operating conditions, during the commissioning phase, or when the prediction model has not converged, a manual fine-tuning amount is superimposed on the reference command current.

[0031] The closed-loop correction involves the PLC control unit or field equipment combining field pressure, flow, temperature and valve feedback signals to perform real-time correction of the executed quantity through PID closed-loop control.

[0032] Compared with existing technologies, this invention does not simply display multiple load objects on the same host computer interface. Instead, it reorganizes the unified control relationship of multiple types of loads through the data flow and control flow between the host computer, PLC control unit, database, and field device layer. This allows electronic loads, hydraulic loads, fuel loads, and bleed air loads to operate independently or collaboratively under unified rules. At the same time, by introducing intelligent prediction of initial control quantities for valve-controlled objects and a PLC closed-loop correction mechanism, the system's automation level, control consistency, and engineering adaptability are improved in multi-condition and multi-load combination scenarios.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] 1. This invention is an integrated control system and method for multiple loads, including electronic loads, hydraulic loads, fuel loads, and bleed air loads. By dividing the host computer, PLC, database, and field devices into interconnected functional levels, and using a unified data interaction link, the four types of loads are incorporated into the same platform, achieving unified operation entry, parameter configuration, status monitoring, and historical data management. Simultaneously, the PLC is equipped with functional modules such as mode matching, synchronization control, data acquisition, and fault response, enabling the PLC to perform condition judgment, interlock constraints, sequential / synchronous control, and anomaly handling between host computer instructions and field execution. This ensures that the joint operation of multiple loads is based on judgment, feedback, and protection, reducing problems such as information dispersion, cumbersome operation, and difficulty in synchronization under existing distributed control methods.

[0035] 2. This invention is an integrated control system and method for multiple types of valve-controlled loads. Addressing the issue that the initial valve positions for branches such as hydraulic loads, fuel loads, and bleed air loads rely heavily on manual experience for setting, resulting in long control response times, an intelligent algorithm prediction mechanism is introduced on the host computer side. This mechanism corrects the initial control quantity based on historical operating data, current operating condition information, and target setpoints, and sends the prediction results to the PLC as the initial execution value. Based on this, the PLC performs closed-loop control and interlocking processing internally, incorporating field feedback. This reduces the reliance on manual experience for initial settings, shortens the control response process, and improves the speed and consistency of load extraction. It also helps reduce the adverse effects of excessive initial input deviations on the field loops, enabling multiple types of valve-controlled objects to obtain more reasonable initial control conditions under a unified control framework.

[0036] 3. This invention is a multi-load integrated control system and control method that combines operation management and data management capabilities. By setting up a data acquisition, storage, query, and export mechanism associated with a database, the status variables, alarm information, and historical records during multi-load operation can be archived in a unified manner. It also supports querying, comparing, and tracing the operation status of different working modes, different load types, and different time periods, providing data basis for fault analysis and parameter adjustment. At the same time, while maintaining the unity of the overall control architecture, this invention does not forcibly merge electronic loads, hydraulic loads, fuel loads, and bleed air loads into the same object model. Instead, it coordinates and controls them through a unified platform interface, a unified command organization method, and a unified interlocking monitoring rule. Thus, while possessing integrated control characteristics, it adapts to the engineering characteristics of different field objects, making it easy to gradually expand and improve on the basis of existing experimental control, and has good engineering adaptability and implementation feasibility. Attached Figure Description

[0037] Figure 1 This is a top-level system architecture diagram of the integrated control system for engine loading power extraction under multiple loads in an embodiment of the present invention;

[0038] Figure 2 This is a schematic diagram of the hydraulic load branch in an embodiment of the present invention;

[0039] Figure 3 This is a schematic diagram of the fuel load branch in an embodiment of the present invention;

[0040] Figure 4 This is a schematic diagram of the structure of the bleed air load branch in an embodiment of the present invention;

[0041] Figure 5 This is a schematic diagram of the electronic load branch in an embodiment of the present invention. Detailed Implementation

[0042] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0043] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0044] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0045] Example 1: Overall System Implementation

[0046] This embodiment provides a multi-load integrated control system for engine-loaded power extraction scenarios. For example... Figure 1 As shown, the system includes a host computer, a PLC control unit, a database, and a field device layer.

[0047] The host computer and PLC control unit are preferably connected via industrial Ethernet and use Modbus TCP for bidirectional data interaction. The database is associated with the host computer and is used to uniformly archive operating data, alarm information, operation records and historical task information. The field device layer includes electronic load branches, hydraulic load branches, fuel load branches and bleed air load branches. Each branch establishes a control and data feedback relationship with the PLC control unit, forming a unified closed-loop control link of host computer → PLC → field device.

[0048] In a typical operation, the operator first selects the load operating mode on the host computer and inputs the target power, target pressure, target flow rate, target valve control quantity, or preset operating condition stage information. The host computer generates a control task based on the selected control method. When the controlled object is a valve-controlled object such as a hydraulic load, fuel load, or bleed air load, the host computer further generates the initial command current for the corresponding branch and sends it to the PLC control unit along with the mode information, stage parameters, and target setpoints. After receiving the relevant task, the PLC control unit judges the start-up conditions, switching conditions, branch allowable conditions, and interlock constraints. When the conditions are met, the corresponding branch is activated in a predetermined order or synchronously. During operation, the PLC control unit continuously collects feedback, corrects control outputs, executes abnormal protection, and transmits status data.

[0049] Example 2: Implementation of Cooperative Control between Host Computer and PLC

[0050] In this embodiment, the host computer is used to perform functions such as organizing power extraction tasks, selecting operating modes, configuring target parameters, selecting operating conditions, generating control commands, displaying status, providing alarm prompts, and managing historical data. Preferably, the host computer includes a manual input control mode and a preset operating condition automatic control mode: in the manual input control mode, the operator directly inputs the target process quantity and issues it for execution; in the preset operating condition automatic control mode, the operator pre-sets the test operating conditions and their phased processes in the PLC, and the host computer only needs to select and issue the operating condition sequence number. After receiving the sequence number, the PLC control unit automatically executes the corresponding control task.

[0051] As the core of the execution layer, the PLC control unit is responsible for instruction parsing, pattern matching, task allocation, operating condition configuration, data acquisition, closed-loop correction, and fault response. For multi-load joint operation, the PLC control unit does not simply start multiple branches simultaneously, but determines the branch activation sequence based on the current status of each branch and the overall operating requirements. When a branch has not yet reached its permissible state, the PLC control unit can keep the corresponding branch in standby or limit its output, and continue executing subsequent tasks once the conditions are met. During operation, the PLC continuously collects signals such as pressure, flow rate, temperature, valve feedback, current, voltage, pump status, motor status, and communication status, and returns them to the host computer for display and storage.

[0052] Example 3: Control Implementation Method for Each Load Branch

[0053] In this embodiment, the hydraulic load branch, fuel load branch, and bleed air load branch all adopt a unified "command current—valve position—flow area—process quantity" control chain. The PLC control unit outputs the command current to the proportional valve or regulating valve. The valve drives the valve core to move according to the command current, causing the valve position to change, thereby changing the effective flow area of ​​the valve orifice, and ultimately achieving the regulation of pressure, flow rate, or power extraction. For ease of uniformity, the command current of the i-th type of valve-controlled branch is defined as... Its normalized aperture coefficient is:

[0054]

[0055] in, Minimum command current, For the maximum command current, preferably, when the proportional valve adopts When inputting, , ; For the amplitude limiting function, This represents the normalized opening degree.

[0056] In a preferred embodiment, the effective flow area of ​​the valve port is approximately linearly related to the normalized opening degree, which can be expressed as:

[0057]

[0058] in, This represents the maximum effective flow area of ​​the valve.

[0059] As can be seen from the above formula, the PLC does not directly control the pressure or flow, but changes the valve position by outputting command current, and then affects the branch process quantity by changing the valve port area.

[0060] 1. Implementation method of hydraulic load branch

[0061] In this embodiment, the hydraulic load branch is as follows: Figure 2 As shown, the system includes two symmetrically arranged hydraulic branches, each comprising an oil supply pump, an unloading unit, a large throttle valve, a small throttle valve, a fixed flow valve, a proportional pressure regulating valve, a flow meter, a pressure relief valve, a pressure gauge, and a flow meter. During operation, the PLC control unit controls the on / off valves, unloading units, and valve settings of the corresponding branches according to the control tasks issued by the host computer, and continuously collects signals such as pressure, flow rate, temperature, and valve feedback.

[0062] In this embodiment, the hydraulic branch mainly operates in constant pressure mode. In constant pressure mode, the pressure measured by pressure gauge 1 is maintained within a predetermined range, and the system primarily extracts the target power by adjusting the flow rate. Before loading, the unloading unit is in the open state; upon entering the loading condition, the unloading unit is closed, and the on / off valve above the proportional pressure regulating valve is closed, while the corresponding on / off valve of the throttling branch is opened. The flow rate reaches the target value by adjusting the large and small throttling valves; the large throttling valve is used for coarse adjustment, and the small throttling valve is used for fine adjustment. During control, it is preferable to adjust the large throttling valve first, then the small throttling valve. When the large throttling valve is completely closed, the system can switch to a small flow meter for flow measurement to improve measurement accuracy under low flow conditions. When a fixed flow rate is required, the throttling branch is closed, and the fixed flow valve and its corresponding on / off valve are opened to achieve a fixed flow rate output. In emergency situations, the unloading unit is directly opened to achieve rapid unloading protection.

[0063] The flow rate of the hydraulic branch can be expressed as:

[0064]

[0065] in, For the hydraulic branch flow rate, For flow coefficient, Let be the effective flow area of ​​the hydraulic valve at time t. The pressure difference across the valve. The density of the hydraulic medium.

[0066] In a preferred embodiment, the effective flow area of ​​the equivalent valve orifice is jointly determined by the large throttle valve and the small throttle valve. The flow area of ​​the large throttle valve is approximately linearly related to its opening degree, which can be expressed as:

[0067]

[0068] in, To maximize the effective flow area of ​​the throttle valve, Geometric coefficients This refers to the large throttle valve opening.

[0069] Small throttle valves employ a fine adjustment method, and their flow area and opening degree can be preferably expressed as an equal percentage relationship:

[0070]

[0071] in, For small throttle valves, This represents the maximum flow area of ​​the small throttle valve. For adjustable range ratio, This refers to the opening degree of the small throttle valve.

[0072] Therefore, the equivalent flow area of ​​the hydraulic branch is:

[0073]

[0074] The power extracted by the hydraulic branch can be expressed as:

[0075]

[0076] in, This refers to the working pressure of the hydraulic branch circuit.

[0077] In this embodiment, when a fixed flow rate is required, the system can switch to the fixed flow rate branch to achieve the corresponding output. The process for generating the reference command current and performing closed-loop correction for the hydraulic branch can be found in Embodiment 4.

[0078] 2. Implementation method of fuel load branch

[0079] In this embodiment, the fuel load branch is as follows: Figure 3 As shown, the system includes a power switch, a bypass regulating valve, a main regulating valve, a pressure gauge, and a flow meter. The PLC control unit outputs a command current to the fuel branch regulating valve based on the control tasks issued by the host computer, and regulates the fuel branch by changing the valve position and the effective flow area of ​​the valve port. During operation, the PLC continuously collects signals such as pressure, flow rate, and valve feedback.

[0080] In a preferred embodiment, the fuel pump output flow rate can be expressed as:

[0081]

[0082] in, This refers to the output flow rate of the fuel pump. For pump displacement, This is the speed of the drive motor.

[0083] The flow rate of the fuel branch after valve adjustment can be expressed as:

[0084]

[0085] in, For fuel branch flow, For flow coefficient, Let be the effective flow area of ​​the fuel valve at time t. The pressure difference across the valve. This refers to the density of the fuel.

[0086] The power extracted from the fuel branch can be expressed as:

[0087]

[0088] in, For the working pressure of the fuel branch circuit.

[0089] The process of generating the reference command current and correcting the closed loop in the fuel branch can be found in Example 4.

[0090] 3. Implementation method of bleed air load branch

[0091] In this embodiment, the bleed air load branch is as follows: Figure 4 As shown, the system includes a regulating valve, a pressure relief valve, a pilot valve, and pressure and flow detection units. The PLC control unit outputs command current to the main regulating valve of the bleed air branch based on the control tasks issued by the host computer, and regulates the bleed air branch by changing the valve position and the effective flow area of ​​the valve port. The pressure relief valve is mainly used for safety protection and overpressure release. During operation, the PLC continuously collects signals such as pressure, flow rate, and valve feedback.

[0092] In a preferred embodiment, the volumetric flow rate of the bleed air branch can be expressed as:

[0093]

[0094] in, The volumetric flow rate of the bleed air branch is... For flow coefficient, The effective flow area of ​​the bleed air main regulating valve at time t. The pressure difference across the valve. The density is the gas density.

[0095] The extraction power of the bleed air branch can be expressed as:

[0096]

[0097] in, The working pressure of the bleed air branch.

[0098] The process of generating the reference command current and correcting the closed loop of the bleed air branch can be found in Example 4.

[0099] 4. Implementation method of electronic load branch

[0100] In this embodiment, the electronic load branch is as follows: Figure 5 As shown, the system includes a six-phase interleaved parallel Boost circuit, an NPC grid-connected inverter, and an LCL filter, which are connected to the integrated control system as the object of electrical load power extraction. Its operating modes include high-voltage mode and low-voltage mode. Operators can select the corresponding mode on the host computer and directly set the input current of the electronic load. The PLC control unit completes the corresponding control task based on the mode information and current setpoint issued by the host computer, and simultaneously receives voltage, current, power, and operating status information returned by the electronic load for unified display, alarm, and archiving by the host computer.

[0101] The power extraction of the electronic load branch can be expressed as:

[0102]

[0103] in, Extract power for the electronic load branch. This is the operating voltage of the electronic load branch. Input current for the electronic load branch.

[0104] In this embodiment, the electronic load branch directly sets the input current to achieve power regulation through the host computer; when the electronic load is working in high voltage mode or low voltage mode, the system calculates the current power extraction amount according to the actual voltage and input current in the corresponding mode, and returns the relevant operating parameters to the host computer for monitoring and recording.

[0105] Example 4: Implementation of Reference Command Current Generation and Closed-Loop Correction for Valve-Controlled Branches

[0106] In this embodiment, to address the issues that valve-controlled loads such as hydraulic loads, fuel loads, and bleed air loads rely primarily on manual experience to provide initial values ​​before entering the target operating condition, resulting in significant dispersion of values ​​provided by different operators and long times to reach the target state, a reference command current generation module is set up in the host computer. Preferably, this module does not directly output the final execution control quantity, but rather generates a reference command current for the valve-controlled branch before it enters the target operating condition, and is used in conjunction with the closed-loop control of the PLC or field equipment.

[0107] In one implementation, the host computer calculates the basic initial command current of the valve-controlled branch based on the target power, target pressure, target flow rate, valve calibration relationship, and constant pressure or constant flow conditions. For operating conditions where power extraction is the input target, it is preferable to first analyze the target flow rate based on the target power and the current pressure setpoint, and then obtain the corresponding basic initial command current based on the valve flow model or empirical calibration curve.

[0108] In another preferred embodiment, the host computer further uses a prediction model to generate a predicted correction amount for the basic initial command current based on historical operating data, current operating condition information, target parameters, historical command current input, and historical feedback data, thereby obtaining a reference command current that is closer to the target state. Preferably, the prediction model is a GRU time-series prediction model; however, other prediction models suitable for time-series data modeling may also be used without departing from the concept of the present invention.

[0109] When manual intervention is required for debugging, operators can also manually increase or decrease the reference command current via the host computer to adapt to the needs of rapid adjustments during special operating conditions, debugging phases, or when the model has not yet converged. Thus, a reference value generation chain is formed on the host computer side: "basic initial value generation - prediction correction - manual fine-tuning".

[0110] In a preferred embodiment, the target flow rate of the valve-controlled branch can be expressed as:

[0111]

[0112] in, For target traffic, For the target power, This is the pressure setting value for the corresponding branch.

[0113] In another preferred embodiment, the host computer further uses a prediction model to generate a predicted correction amount for the basic initial command current based on historical operating data, current operating condition information, target parameters, historical command current input, and historical feedback data, thereby obtaining a reference command current that is closer to the target state. Preferably, the prediction model is a time-series prediction model; more preferably, the prediction model is a GRU model. The prediction model does not directly replace the mechanistic analysis results, but is used to compensate for errors caused by valve nonlinearity, hysteresis, object coupling, environmental disturbances, and operating condition switching that are difficult to fully describe by mechanistic / calibration methods.

[0114] During the model training phase, a candidate feature set is first constructed. These candidate features may include load type, operating mode, operating condition stage identifier, target power, target pressure, target flow rate, basic initial command current obtained from mechanism analysis, pressure difference across the valve, historical command current sequence, historical flow feedback sequence, historical pressure feedback sequence, temperature information, valve feedback information, and other operating parameters related to the target operating condition. Then, a feature selection algorithm with feature importance assessment capabilities is used to filter the candidate features, selecting feature combinations with higher contribution as input to the prediction model. Preferably, the feature selection algorithm is XGBoost.

[0115] In a preferred embodiment, the filtered feature sequence is input into the GRU model, and the output is a predicted correction value for the basic initial command current. The model input state vector can be represented as:

[0116]

[0117] in, This serves as an identifier for the current load pattern or phase. This is the current operating condition information. These are the target power, target pressure, and target flow rate, respectively. The basic initial command current obtained from the mechanism analysis, This refers to the feature combination after feature filtering.

[0118] In a preferred embodiment, the label of the prediction correction model is defined as:

[0119]

[0120] in, This is the actual correction value. This refers to the actual control current in historical samples that, under the corresponding target operating conditions, resulted in the actual flow rate reaching the target range or stabilizing within the allowable error band. This is the basic initial command current calculated from the mechanism / calibration relationship under the same operating conditions.

[0121] The correction value output by the prediction model can be expressed as The reference command current generated by the host computer can be expressed as:

[0122]

[0123] in, For reference command current, The basic initial command current is calculated based on the mechanism / calibration relationship. This is the correction amount for the output of the prediction model. This is for manual fine-tuning.

[0124] Upon receiving the reference command current, the PLC or field device does not directly rely on the host computer model to independently complete the control. Instead, it combines field signals such as pressure, flow rate, temperature, and valve feedback, and uses PID or other closed-loop control methods to perform real-time correction and interlocking of the executed quantity. When flow rate is the primary closed-loop regulation object, the flow rate deviation can be expressed as:

[0125]

[0126] in, For target traffic, This represents the actual traffic volume.

[0127] In this way, on the one hand, the reliance on human experience for initial settings can be reduced, and executable basic initial values ​​can still be obtained by relying on mechanism / calibration relationship when data is insufficient or the model fails; on the other hand, predictive models can be used to compensate for nonlinearity and coupling errors that are difficult for mechanism models to cover accurately, thereby improving the speed and consistency of the system entering the target state; at the same time, the manual fine-tuning interface and on-site PID closed-loop control ensure the system's debuggability, stability and engineering adaptability during the commissioning phase, under special working conditions and real-time disturbance conditions.

[0128] Example 5: Data Management and Operation Monitoring Implementation Method

[0129] In this embodiment, the database is associated with the host computer to uniformly archive status variables, alarm information, stage task information, operation records, and historical data during multi-load operation. The database categorizes and stores data according to operating mode, load type, time, operating condition stage, and alarm category. The data stored in the database includes at least target setpoints, control output values, real-time feedback values, alarm information, fault records, operation records, and date information.

[0130] The host computer continuously receives operating status and anomaly information uploaded by the PLC and writes key parameters and timestamps into the database according to a unified format to support subsequent data querying, exporting, comparison, and backtracking. Through this mechanism, operators can analyze the operating conditions under different working modes, different load combinations, and different time periods, and backtrack the operating process after anomalies occur, providing data basis for fault analysis and parameter adjustment.

[0131] In the implementation of this invention, the database is not only used to store real-time operating data, but also to accumulate historical samples corresponding to different operating conditions, different branch combinations, and different control results, providing a data foundation for the training, updating, and verification of the subsequent intelligent prediction model. As the number of historical samples increases, the system can continuously enrich the mapping relationship between the target operating condition and the initial control quantity, making the initial prediction value generated by the host computer more consistent with the actual operating rules, thereby further improving the system's adaptability in multiple scenarios.

[0132] In summary, the technical solution of this invention does not simply display multiple load objects on the same interface. Instead, it unifies the system structure around the data and control flows between the host computer, PLC, database, and field devices: the host computer handles task-level configuration, operating condition management, initial control quantity generation, and operation monitoring; the PLC handles logic judgment, task allocation, interlock constraints, and closed-loop control; the field devices handle object-level execution responses; and the database handles data archiving and management. Electronic loads, hydraulic loads, fuel loads, and bleed air loads can operate independently or collaboratively under unified rules, thus forming a multi-load integrated control system and its control method suitable for multiple scenarios.

[0133] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A multi-load integrated control system for extracting engine loading power, characterized in that, This includes the host computer, PLC control unit, database, and field device layer; The host computer is used for selecting operating modes, configuring load combinations, setting target parameters, selecting operating conditions, generating control commands, displaying operating status, providing alarm prompts, and managing historical data. The PLC control unit is used to receive control commands, mode information and target parameters issued by the host computer, and to perform logical judgment, task allocation, timing coordination, status acquisition, control output, interlock protection, closed-loop correction and fault response. The database is used for unified storage, classification management, and traceability analysis of operational data, alarm information, operation records, and historical task information; The field device layer includes electronic load branches, hydraulic load branches, fuel load branches, and bleed air load branches. Each branch establishes a signal interaction relationship with the PLC control unit to form a unified closed-loop control link between the host computer, PLC, and field devices.

2. The integrated control system for extracting engine power under multiple loads according to claim 1, characterized in that, The host computer and the PLC control unit communicate bidirectionally via industrial Ethernet, using Modbus TCP communication. The host computer acts as the master station, sending control parameters and reading status data from the PLC control unit. The PLC control unit uploads the operating status of each branch, feedback parameters, alarm information, and fault status to the host computer.

3. The integrated control system for extracting engine loading power under multiple loads according to claim 1, characterized in that, The PLC control unit is internally equipped with an instruction parsing and pattern matching module, a task allocation and sequence control module, a synchronization and coordination module, a data acquisition module, a closed-loop correction module, and a fault response module. Among them, the task allocation and sequence control module is used to organize the start-up, switching, holding, and exit processes of each load branch according to the current equipment status, allowable conditions, and interlocking constraints. The closed-loop correction module is used to correct the execution quantity in real time based on the field feedback.

4. The integrated control system for extracting engine loading power under multiple loads according to claim 1, characterized in that, The host computer includes a manual input control mode and a preset working condition automatic control mode. In the manual input control mode, the operator directly inputs the target power, target pressure, target flow rate, or target valve position, which is then processed by the host computer and sent to the PLC control unit for execution. In the preset working condition automatic control mode, the operator pre-sets the target working condition and its stage process, and the host computer selects the working condition number and sends it to the PLC control unit, which then automatically executes the entire task process.

5. The integrated control system for extracting engine loading power under multiple loads according to claim 1, characterized in that, The hydraulic load branch includes an oil supply pump, an unloading unit, a throttle valve, a fixed flow unit, a proportional pressure regulating valve, a flow meter, a pressure relief valve, and a pressure gauge; the fuel load branch includes a pressure gauge, a flow meter, a power switch, a bypass regulating valve, and a main regulating valve; the bleed air load branch includes a regulating valve, a pilot valve, a pressure relief valve, and a pressure and flow detection unit; the electronic load branch is used to extract the electrical load power according to the mode information and input current set by the host computer, and return voltage, current, power, and operating status information to the host computer.

6. The integrated control system for extracting engine loading power under multiple loads according to claim 1, characterized in that, For hydraulic load branches, fuel load branches, and bleed air load branches, the host computer is equipped with a reference command current generation module. The reference command current generation module first generates a basic initial command current based on the target operating conditions, target flow rate, valve calibration relationship, and operating constraints. Then, it generates a predicted correction amount for the basic initial command current based on historical operating data, current operating condition information, target parameters, historical command current inputs, and historical feedback results to obtain the reference command current. The host computer sends the reference command current to the PLC control unit as an execution reference value. The PLC control unit or field equipment combines the field feedback amount to perform subsequent corrections on the execution amount through closed-loop control.

7. The integrated control system for extracting engine loading power under multiple loads according to claim 6, characterized in that, The reference command current generation module is also equipped with a manual fine-tuning interface, which is used to manually increase or decrease the reference command current under special operating conditions, during the debugging stage, or when the prediction model has not converged. The prediction correction amount is output by the time series prediction model, and the input features of the time series prediction model are obtained by filtering the candidate feature set through a feature screening algorithm with feature importance evaluation capability.

8. The integrated multi-load control system for engine loading power extraction according to claim 6, characterized in that, The database is associated with the host computer and is used to classify and store data according to operating mode, load type, time, operating condition stage and alarm category. The data stored in the database includes at least target set value, control output value, real-time feedback value, alarm information, fault record, operation record and date information. The historical data in the database is used for the training, updating and verification of the command current generation module.

9. A multi-load integrated control method for extracting engine loading power based on the system described in any one of claims 1-8, characterized in that, include: Select the operating mode in the host computer according to the target test scenario, and input the target power, target pressure, target flow rate, target valve position or preset operating condition number; The host computer generates control tasks; for the hydraulic load branch, fuel load branch, and bleed air load branch, reference command currents are further generated. The control task, target parameters, and reference command current are sent to the PLC control unit. The PLC control unit judges and assigns tasks based on the current status, permissible conditions, and interlocking rules, and drives the corresponding branches to execute in a set sequence; During operation, the status and feedback quantities of each branch are collected in real time, and closed-loop correction is performed based on the deviation between the target value and the feedback value. Write operational information, alarm information, and historical task information into the database.

10. The integrated control method for extracting engine loading power under multiple loads according to claim 9, characterized in that, The generated reference command current includes: Based on the target power, target pressure setpoint and / or target flow rate, and combined with the valve flow model or empirical calibration relationship, a basic initial command current is generated; Based on historical operating data, current operating condition information, target parameters, historical command current and historical feedback data, a predicted correction amount is generated, and the predicted correction amount is superimposed on the basic initial command current to obtain the reference command current. In special operating conditions, during the commissioning phase, or when the prediction model has not converged, a manual fine-tuning amount is superimposed on the reference command current. The closed-loop correction involves the PLC control unit or field equipment combining field pressure, flow, temperature and valve feedback signals to perform real-time correction of the executed quantity through PID closed-loop control.

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