A functional simulation control panel used in diesel generator control systems

Abstract

The present invention discloses a functional simulation control panel applied to a diesel generator control system, comprising a frequency converter, a three-phase motor, a generator, an electric power meter, a human-machine interface, a controller, a load unit, an analog quantity unit and a quick-plug terminal, wherein the frequency converter, the three-phase motor, the generator, the electric power meter, the human-machine interface, the controller and the load unit are connected in sequence; the generator is connected to the load unit; an automatic voltage regulator is arranged on the generator; the frequency converter, the automatic voltage regulator, the controller and the analog quantity unit are respectively connected to the quick-plug terminal; a potentiometer is arranged in the analog quantity unit. The functional simulation control panel applied to a diesel generator control system of the present invention can simulate the required functions quickly and efficiently, can conveniently reproduce faults in actual applications, facilitate fault finding, and can cooperate with a dedicated controller for diesel generators to conveniently demonstrate its functions.

Description

Technical Field

[0001] The invention relates to a function simulation control panel applied to a diesel generator control system. Background Art

[0002] A diesel generator set is a power generation equipment composed of a diesel engine, a generator, a control box, a fuel tank, a starting and control battery, a power distribution cabinet and other components. The core component of the electronic control system is the control box, and the core of the control box is the diesel generator controller. The diesel generator controller is a professional PLC unit that highly integrates digital display function, logic programming function, and power distribution protection function. In practical applications, it is often troublesome to verify the function of the diesel generator controller. When doing operation training, fault reproduction of diesel generator sets, and early control system design, it is necessary to use the generator set to configure the corresponding diesel generator controller for real startup operation, simulate and reproduce the required functions, so as to meet training needs, find faults, and verify design functions. If several test prototypes of generator sets are configured in the laboratory, the cost is high and space is occupied; if the secondary control line is temporarily connected to the diesel generator controller for testing, it will take a long time. If the diesel generator controller of other brands and models is replaced, it is often necessary to rewire; and after the diesel generator set is started, it will also produce relatively large noise, exhaust smoke, etc., and consume diesel fuel. It can be said that using this method to simulate functions is not only inefficient, wastes fuel, is costly, and is not environmentally friendly. At this time, a device is needed that is easy to operate and can perform the required functions for simulating the test of the diesel generator dedicated controller. Summary of the invention

[0003] The purpose of the present invention is to overcome the defects of the prior art and provide a functional simulation control panel applied to a diesel generator control system, which can quickly and efficiently simulate the required functions, can easily reproduce faults in actual applications, facilitate fault finding, and can be used in conjunction with a dedicated controller for a diesel generator to conveniently demonstrate its functions for operation training purposes.

[0004] The technical solution to achieve the above purpose is: a functional simulation control panel applied to a diesel generator control system, an external diesel generator dedicated controller, the functional simulation control panel includes a frequency converter, a three-phase motor, a generator, a power meter, a human-machine interface (HMI), a controller (PLC), a load unit, an analog quantity unit and a quick-plug terminal, wherein:

[0005] The frequency converter is externally connected to a mains power supply;

[0006] The frequency converter, three-phase motor, generator, power meter, human-machine interface, controller and load unit are connected in sequence;

[0007] The generator is connected to the load unit, and a current detection transformer is provided on the line between the generator and the load unit;

[0008] The generator is provided with an automatic voltage regulator (AVR);

[0009] The frequency converter, automatic voltage regulator, controller and analog quantity unit are respectively connected to the quick-plug terminals;

[0010] A potentiometer is provided in the analog quantity unit;

[0011] The diesel generator dedicated controller is connected to the quick-plug terminal.

[0012] The above-mentioned functional simulation control panel applied to the diesel generator control system, wherein a first circuit breaker is arranged on the line between the AC power supply and the frequency converter; a second circuit breaker is arranged on the line between the frequency converter and the three-phase motor; and a third circuit breaker and a contactor are also arranged on the line between the generator and the load unit.

[0013] The above-mentioned functional simulation control panel applied to the diesel generator control system, wherein the mains power supply is used to provide a stable three-phase power supply for the frequency converter;

[0014] The potentiometer in the analog quantity unit sends an analog resistance signal to the dedicated controller for the diesel generator;

[0015] The frequency converter receives a speed regulation signal from the dedicated controller of the diesel generator, and outputs a three-phase power supply according to the speed regulation signal to change the speed of the three-phase motor;

[0016] The three-phase motor provides a mechanical rotation power source for the generator;

[0017] The automatic voltage regulator receives a voltage regulation signal from the diesel generator dedicated controller, and controls the three-phase power output by the generator according to the voltage regulation signal;

[0018] The diesel generator dedicated controller and the power meter respectively collect voltage signals of the three-phase power supply output by the generator through the voltage collection signal line;

[0019] The current detection transformer detects the current signal of the three-phase power supply output by the generator, and transmits the current signal to the diesel generator dedicated controller and the power meter through the current detection signal line respectively;

[0020] The power meter transmits the received voltage signal and current signal of the three-phase power supply output by the generator to the human-machine interface through the first communication line respectively;

[0021] The human-machine interface displays the voltage, current, active power and reactive power of the diesel generator dedicated controller through the second communication line;

[0022] The diesel generator dedicated controller issues a generator load command, the generator outputs a three-phase load busbar that meets the load condition, and the diesel generator dedicated controller collects a voltage signal of the three-phase load busbar;

[0023] The human-machine interface sends instructions to the controller through the third communication line, and the controller outputs a switch signal according to the instruction of the human-machine interface, and transmits the switch signal to the dedicated controller for the diesel generator;

[0024] The human-machine interface sends a load test instruction to the controller via a third communication line, and the controller outputs a corresponding loading command to the load unit according to the load test instruction from the human-machine interface.

[0025] The above-mentioned functional simulation control panel is applied to the diesel generator control system, wherein the potentiometer in the analog unit adjusts the resistance value of the output analog resistance signal to change the state of the engine oil pressure, water temperature, oil level and oil temperature parameters in the diesel generator dedicated controller.

[0026] The functional simulation control panel applied to the diesel generator control system of the present invention has the following advantages:

[0027] (1) The simulation control panel can simulate the required functions quickly and efficiently, can easily reproduce the faults in actual applications, and can be used to find faults. It can be used with the diesel generator dedicated controller to conveniently demonstrate its functions for operation training;

[0028] (2) The simulation function of the simulation control panel is fast and effective. Instead of wiring on the unit, you only need to plug the corresponding quick-plug terminal into the dedicated controller of the diesel generator, and the wiring can be completed in a moment, which shortens the operation that a skilled technician would have to do for more than two hours, greatly improving the efficiency of the simulation test. Especially in the parallel function test, in practice, it is necessary to complete the parallel connection of two or more units, and the preliminary preparation work consumes a lot of time and occupies a relatively large number of test benches. However, it is much simpler to use the parallel simulation control panel to perform the test.

[0029] (3) The power supply of the simulation control panel adopts the form of AC power supply and driving electric motor, which replaces the diesel engine in actual application. There is no air pollution, noise pollution, and no diesel consumption in the test. The test cost is much lower than the cost generated by the actual consumption of diesel. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1It is a structural schematic diagram of a functional simulation control panel applied to a diesel generator control system of the present invention;

[0031] Figure 2 The figure is a working principle diagram of the functional simulation control panel applied to the diesel generator control system of the present invention. DETAILED DESCRIPTION

[0032] In order to enable those skilled in the art to better understand the technical solution of the present invention, the specific implementation methods thereof are described in detail below in conjunction with the accompanying drawings:

[0033] See also Figure 1 and Figure 2 The best embodiment of the present invention is a functional simulation control panel applied to a diesel generator control system, comprising a frequency converter 1, a three-phase motor 2, a generator 9, a power meter 3, a human-machine interface 9 (HMI) 4, a controller (PLC) 5, a load unit 10, an analog quantity unit 6 and a quick-plug terminal 7.

[0034] The inverter 1 is connected to an external mains power supply 11; the inverter 1, the three-phase motor 2, the generator 9, the power meter 3, the human-machine interface 4, the controller 5 and the load unit 10 are connected in sequence; the generator 9 is connected to the load unit 10, and a current detection transformer 13 is provided on the line between the generator 9 and the load unit 10; the generator 9 is provided with an automatic voltage regulator (AVR) 8; the inverter 1, the automatic voltage regulator 8, the controller 5 and the analog unit 6 are respectively connected to the quick-plug terminal 7; the analog unit 6 is provided with a potentiometer. A first circuit breaker Q1 is provided on the line between the mains power supply 11 and the inverter 1; a second circuit breaker Q2 is provided on the line between the inverter 1 and the three-phase motor 2; a third circuit breaker Q3 and a contactor KM are also provided on the line between the generator 9 and the load unit 10.

[0035] The functional simulation control panel applied to the diesel generator control system of the present invention is directly connected to the diesel generator dedicated controller 12 through the quick plug terminal 7 when in use. The functions of each component are as follows:

[0036] (1) The mains power supply 11 is used to provide a stable three-phase power supply A1 for the inverter 1;

[0037] (2) The potentiometer in the analog quantity unit 6 sends an analog resistance signal B1 to the diesel generator dedicated controller 12. The potentiometer in the analog quantity unit 6 adjusts the resistance value of the output analog resistance signal B1 to change the states of the engine oil pressure, water temperature, oil level and oil temperature parameters in the diesel generator dedicated controller 12;

[0038] (3) The frequency converter 1 receives the speed control signal B2 from the diesel generator dedicated controller 12, and outputs the three-phase power supply A2 according to the speed control signal B2 to change the speed of the three-phase motor 2;

[0039] (4) The three-phase motor 2 provides a mechanical rotation power source for the generator 9;

[0040] (5) The automatic voltage regulator 8 receives the voltage regulation signal B3 from the diesel generator dedicated controller 12, and controls the three-phase power supply A3 output by the generator 9 according to the voltage regulation signal B3;

[0041] (7) The diesel generator dedicated controller 12 and the power meter 3 collect the voltage signal of the three-phase power supply A3 output by the generator 9 through the voltage collection signal lines B4 and A7 respectively;

[0042] (8) The current detection transformer 13 detects the current signal of the three-phase power supply A3 output by the generator 9, and transmits the current signal to the diesel generator dedicated controller 12 and the power meter 3 through the current detection signal lines B8 and A6 respectively;

[0043] (9) The power meter 3 transmits the voltage signal and current signal of the three-phase power supply A3 output by the generator 9 to the human-machine interface 4 through the first communication line A8;

[0044] (10) The human-machine interface 4 displays the voltage, current, active power and reactive power of the diesel generator dedicated controller 12 through the second communication line B9;

[0045] (11) The dedicated controller 12 for the diesel generator issues a generator load command B7, the generator 9 outputs a three-phase load busbar A4 that meets the load condition, and the dedicated controller 12 for the diesel generator collects a voltage signal B5 of the three-phase load busbar A4;

[0046] (12) The human-machine interface 4 sends a command to the controller 5 through the third communication line A9. The controller 5 outputs a switch signal B6 according to the command of the human-machine interface 4 and transmits the switch signal B6 to the dedicated controller 12 for the diesel generator;

[0047] (13) The human-machine interface 4 sends a load test instruction to the controller 5 through the third communication line A9. The controller 5 outputs a corresponding loading command A5 to the load unit 10 according to the load test instruction from the human-machine interface 4, that is, the corresponding relay coil output of the controller 5 is put into the corresponding load unit 10.

[0048] The functional simulation control panel applied to the diesel generator control system of the present invention has the following working principle:

[0049] 1. Single machine simulation test

[0050] (1.1) Startup simulation of diesel generator dedicated controller 12

[0051] Start the diesel generator dedicated controller 12, then the frequency converter 1 starts, the frequency converter 1 outputs the changed three-phase power supply A2, the second circuit breaker Q2 is closed, the three-phase motor 2 is started, and the speed of the three-phase motor 2 increases from 0rpm to the rated speed, thereby increasing the speed of the connected generator 9 from 0rpm to the rated speed through mechanical transmission, and the voltage of the three-phase power supply A3 output by the generator 9 also increases from 0V to the rated voltage.

[0052] (1.2) Engine parameter simulation

[0053] The potentiometer in the analog unit 6 sends an analog resistance signal B1 to the diesel generator dedicated controller 12. By adjusting the resistance value of the analog resistance signal B1, the states of parameters such as engine oil pressure, water temperature, oil level, and oil temperature in the diesel generator dedicated controller 12 are changed, thereby verifying the rationality of the protection settings in this regard in the diesel generator dedicated controller 12 and reproducing faults caused by configuration parameter errors during operation.

[0054] (1.3) Customized switch quantity simulation of diesel generator dedicated controller 12

[0055] By operating the configuration button on the human-machine interface 4, the human-machine interface 4 sends an instruction through the third communication line A9 to set the register coil corresponding to the controller 5. The controller 5 sends a switch signal B6 according to the instruction of the human-machine interface 4 and transmits the switch signal B6 to the diesel generator dedicated controller 12 for simulation.

[0056] (1.4) Load state simulation of diesel generator dedicated controller 12

[0057] Operate the load button on the diesel generator dedicated controller 12, the diesel generator dedicated controller 12 sends a generator load command B7, the contactor KM is energized, the three-phase power output by the generator 9 passes through the third circuit breaker Q3, and reaches the three-phase load bus A4. By operating the configuration button on the human-machine interface 4, the human-machine interface 4 sends a load test instruction to the controller 5 through the third communication line A9. The controller 5 receives the load power corresponding to the load test instruction of the human-machine interface 4 through the third communication line A9. The controller 5 outputs the corresponding loading command A5 to the load unit 10 according to the load test instruction from the human-machine interface 4, that is, the corresponding relay coil of the controller 5 is output and the corresponding load unit 10 is put into operation.

[0058] 2Parallel test

[0059] At least two sets of simulation control panels of the present invention are required to be connected to the dedicated controller 12 for the diesel generator, and the three-phase load busbars A4 in the two sets of simulation panel devices are connected by cables.

[0060] (2.1) Manual parallel test

[0061] First, start a set of simulation control screens of the present invention: operate the start button on the diesel generator dedicated controller 12, then the frequency converter 1 starts, the frequency converter 1 outputs the changed three-phase power supply A2, starts the three-phase motor 2, and the speed of the three-phase motor 2 starts to increase from 0rpm to the rated speed, so that the speed of the generator 9 connected together is increased from 0rpm to the rated speed through mechanical transmission, and the voltage of the three-phase power supply A3 output by the generator 9 also increases from 0V to the rated voltage; by operating the closing button on the diesel generator dedicated controller 12, the diesel generator dedicated controller 12 determines whether to execute the closing command according to the internal logic, and if the closing command is executed, the contactor KM is actuated, and the three-phase power supply A3 output by the generator 9 is closed to the three-phase load busbar A4;

[0062] Manually operate another set of analog control panels of the present invention according to the above operation. After successful startup, operate the closing button on the diesel generator dedicated controller 12. The diesel generator dedicated controller 12 compares the voltage signal B5 of the three-phase load bus A4 with the voltage signal of the three-phase power supply A3 output by the generator 9. If the voltage difference, frequency difference and phase angle between the two are within the threshold range, the diesel generator dedicated controller 12 issues a closing command, the contactor KM operates, and the three-phase power supply A3 output by the generator 9 is closed to the three-phase load bus A4; if the voltage difference and frequency difference between the two are beyond the threshold range, the diesel generator dedicated controller 12 issues a closing command. The speed regulation signal B2 is sent to the frequency converter 1, and the frequency converter 1 adjusts the output three-phase power supply A2, thereby changing the speed of the three-phase motor 2; the dedicated controller 12 for diesel generators sends a voltage regulation signal B3 to the automatic voltage regulator 8 of the generator 9, until the voltage difference, frequency difference and phase angle between the three-phase power supply A3 output by the generator 9 and the three-phase load bus A4 are adjusted to within the threshold range, and the manual parallel connection is successful. By operating the configuration button on the human-machine interface 4, the human-machine interface 4 sends a load test instruction through the third communication line A9, and the controller 5 receives the load test instruction from the human-machine interface 4, and the corresponding relay coil of the controller 5 outputs and puts the corresponding load unit 10 into operation. After the manual parallel connection is successful, the power meter 3 transmits the power, voltage, current and other information consumed by the load unit 10 to the human-machine interface 4 through the first communication line A8, and the human-machine interface 4 displays the main parameters such as voltage, current, active power and reactive power in the dedicated controller 12 for diesel generators through the second communication line B9, so as to conveniently and intuitively verify the power distribution and no-load circulation status between the dedicated controllers 12 for diesel generators.

[0063] (2.2) Automatic parallel test

[0064] The dedicated controller 12 for diesel generator is in automatic mode, and sends out a simulated start command through the human-machine interface 4. The controller 5 executes the switch quantity command to the dedicated controller 12 for diesel generator, and the inverter 1 starts. The inverter 1 outputs the changed three-phase power supply A2, starts the three-phase motor 2, and the speed of the three-phase motor 2 starts to rise from 0rpm to the rated speed, thereby increasing the speed of the connected generator 9 from 0rpm to the rated speed through mechanical transmission, and the voltage of the three-phase power supply A3 output by the generator 9 also rises from 0V to the rated voltage; the dedicated controller 12 for diesel generator collects the voltage signal B5 of the three-phase load bus A4. If the three-phase load bus A4 has no voltage, any dedicated controller 12 for diesel generator that meets the closing condition will first execute the closing command. If the closing command is executed, the contactor KM will act, and the three-phase power output by the generator 9 will be closed to the three-phase load bus A4 that meets the load condition; after another set of simulated control panels are automatically started successfully, the dedicated controller 12 for diesel generator will connect the voltage signal B5 of the three-phase load bus A4 to the generator 9 by connecting the voltage signal B5 of the three-phase load bus A4 to the generator 9. The voltage signal of the three-phase power supply A3 output by the motor 9 is compared. If the voltage difference, frequency difference and phase angle of the two are within the threshold range, the diesel generator dedicated controller 12 issues a closing command, the contactor KM is actuated, and the three-phase power supply A3 output by the generator 9 is closed to the three-phase load bus A4; if the voltage difference and frequency difference between the two are beyond the threshold range, the diesel generator dedicated controller 12 outputs a speed regulation signal B2 to the inverter 1, and the inverter 1 adjusts the output three-phase power supply A2, thereby changing the speed of the three-phase motor 2; the diesel generator dedicated controller 12 sends a voltage regulation signal B3 to the automatic voltage regulator 8 of the generator 9 until the voltage difference, frequency difference and phase angle of the three-phase power supply A3 output by the generator 9 and the three-phase load bus A4 are adjusted to within the threshold range, and the automatic parallel connection is successful. By operating the configuration button on the human-machine interface 4, the human-machine interface 4 sends a load test instruction through the third communication line A9, and the controller 5 receives the load test instruction from the human-machine interface 4, and the corresponding relay coil of the controller 5 outputs and puts the corresponding load unit 10 into operation. After the automatic parallel connection is successful, the power meter 3 transmits the power, voltage, current and other information consumed by the load unit 10 to the human-machine interface 4 through the first communication line A8. The human-machine interface 4 displays the main parameters such as voltage, current, active power and reactive power in the diesel generator dedicated controller 12 through the second communication line B9, which is convenient and intuitive to verify the power distribution and no-load circulation status between the diesel generator dedicated controllers 12. By operating the load addition and subtraction of the human-machine interface 4, the power management function of the diesel generator dedicated controller 12 is verified.

[0065] In summary, the functional simulation control panel applied to the diesel generator control system of the present invention can simulate the required functions quickly and efficiently, can easily reproduce faults in actual applications, facilitate fault finding, and can be used in conjunction with a dedicated controller for the diesel generator to conveniently demonstrate its functions for operation training purposes.

[0066] Those skilled in the art should recognize that the above embodiments are only used to illustrate the present invention, and are not intended to limit the present invention. As long as they are within the spirit of the present invention, any changes or modifications to the above embodiments will fall within the scope of the claims of the present invention.

Claims

1. A functional simulation control panel applied to a diesel generator control system, connected to an external diesel generator dedicated controller, characterized in that: The functional simulation control panel includes a frequency converter, a three-phase motor, a generator, a power meter, a human-machine interface, a controller, a load unit, an analog quantity unit and a quick-plug terminal, wherein: The frequency converter is externally connected to a mains power supply; The frequency converter, three-phase motor, generator, power meter, human-machine interface, controller and load unit are connected in sequence; The generator is connected to the load unit, and a current detection transformer is provided on the line between the generator and the load unit; The generator is provided with an automatic voltage regulator; The frequency converter, automatic voltage regulator, controller and analog quantity unit are respectively connected to the quick-plug terminals; A potentiometer is provided in the analog quantity unit; The diesel generator dedicated controller is connected to the quick-plug terminal. The mains power supply is used to provide a stable three-phase power supply for the frequency converter; The potentiometer in the analog quantity unit sends an analog resistance signal to the dedicated controller for the diesel generator; The frequency converter receives a speed regulation signal from the dedicated controller of the diesel generator, and outputs a three-phase power supply according to the speed regulation signal to change the speed of the three-phase motor; The three-phase motor provides a mechanical rotation power source for the generator; The automatic voltage regulator receives a voltage regulation signal from the diesel generator dedicated controller, and controls the three-phase power output by the generator according to the voltage regulation signal; The diesel generator dedicated controller and the power meter respectively collect voltage signals of the three-phase power supply output by the generator through the voltage collection signal line; The current detection transformer detects the current signal of the three-phase power supply output by the generator, and transmits the current signal to the diesel generator dedicated controller and the power meter through the current detection signal line respectively; The power meter transmits the received voltage signal and current signal of the three-phase power supply output by the generator to the human-machine interface through the first communication line respectively; The human-machine interface displays the voltage, current, active power and reactive power of the diesel generator dedicated controller through the second communication line; The diesel generator dedicated controller issues a generator load command, the generator outputs a three-phase load busbar that meets the load condition, and the diesel generator dedicated controller collects a voltage signal of the three-phase load busbar; The human-machine interface sends instructions to the controller through the third communication line, and the controller outputs a switch signal according to the instruction of the human-machine interface, and transmits the switch signal to the dedicated controller for the diesel generator; The human-machine interface sends a load test instruction to the controller through a third communication line, and the controller outputs a corresponding loading command to the load unit according to the load test instruction from the human-machine interface. The potentiometer in the analog quantity unit adjusts the resistance value of the analog resistance signal output, changing the state of the engine oil pressure, water temperature, oil level and oil temperature parameters in the diesel generator dedicated controller; A first circuit breaker is provided on the line between the commercial power supply and the frequency converter; a second circuit breaker is provided on the line between the frequency converter and the three-phase motor; a third circuit breaker and a contactor are also provided on the line between the generator and the load unit; The load state simulation of the dedicated controller for diesel generators includes: operating the load button on the dedicated controller for diesel generators, the dedicated controller for diesel generators issues a generator load command, the contactor is energized, and the three-phase power output by the generator passes through the third circuit breaker to reach the three-phase load busbar, and by operating the configuration button on the human-machine interface, the human-machine interface sends a load test instruction to the controller through the third communication line, the controller receives the load power corresponding to the load test instruction of the human-machine interface through the third communication line, and the controller outputs the corresponding loading command to the load unit according to the load test instruction from the human-machine interface.

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