A loading detection system for a transmission test bench

Abstract

The invention discloses a loading detection system of a transmission test bench, including a transmission system and a detection system; the transmission system includes an incoming power supply, a transformer, an incoming switch cabinet, a rectifier cabinet, a first inverter cabinet, a second inverter cabinet, a switching cabinet, a filter cabinet, a high-voltage starter cabinet, a low-voltage starter cabinet, a first frequency converter, a second frequency converter, a motor and a tested motor; the incoming power supply is connected to the transformer; the transformer is connected to the incoming switch cabinet; the incoming switch cabinet is connected to the rectifier cabinet; the rectifier cabinet is respectively connected to the first inverter cabinet and the second inverter cabinet; the first inverter cabinet is connected to the motor; the second inverter cabinet is connected to the switching cabinet; one end of the switching cabinet is connected to the motor; the other end is connected to the filter cabinet; the output end of the filter cabinet is respectively connected to the high-voltage starter cabinet and the low-voltage starter cabinet; the high-voltage starter cabinet and the low-voltage starter cabinet are respectively connected to the first frequency converter and the second frequency converter; the second frequency converter is connected to the tested motor. This scheme reduces the probability of errors caused by manual operation and improves work efficiency.

Description

Technical Field

[0001] The invention relates to mechanical manufacturing technology, and in particular to a loading detection system of a transmission test bench. Background Art

[0002] The multifunctional transmission test bench is composed of a frequency converter, coupling, variable frequency motor, transformer, power supply and distribution switch, sensor, control system and industrial computer, as well as experimental monitoring and testing software. The measurement of system performance parameters is controlled by the test software. The mechanical efficiency meter is used to collect the signal of the torque and speed sensor, and the FLUKE power meter is used to collect the electrical parameter signal, which is transmitted to the test software through communication. Taking the reducer test as an example, it is divided into no-load test, efficiency test, temperature rise test and overload test. The currently designed reducer uses a single device to manually start the mechanical loading test, and a single experimental project is started separately, which is easy to cause cumbersome tests and operational errors.

[0003] It can be seen that in view of the above situation, there is an urgent need to invent an efficient loading detection device as a problem to be solved in this field. Summary of the invention

[0004] Aiming at the technical problem that the existing test bench adopts a manual single start mode when performing loading experiments, resulting in cumbersome operation and errors, the purpose of the present invention is to provide a loading detection system for a transmission test bench, which effectively solves the problems existing in the prior art.

[0005] In order to achieve the above-mentioned object, the present invention provides a loading detection system for a transmission test bench, including a transmission system and a detection system; the transmission system is composed of an incoming power supply, a transformer, an incoming switch cabinet, a rectifier cabinet, a first inverter cabinet, a second inverter cabinet, a switching cabinet, a filter cabinet, a plurality of starter cabinets, a plurality of junction boxes, a plurality of frequency converters, and a plurality of motors;

[0006] The incoming power supply is connected to the transformer, and the incoming power supply is supplied to the entire transmission system after passing through the transformer;

[0007] The transformer is connected to the incoming switch cabinet, which is the main distribution switch of the transmission system and is used to close or disconnect the power supply;

[0008] The incoming switch cabinet is connected to the rectifier cabinet;

[0009] The rectifier cabinet is connected to the first inverter cabinet and the second inverter cabinet respectively;

[0010] The first inverter cabinet corresponds to the torque and speed mode and is connected to the motor through the junction box;

[0011] The second inverter cabinet corresponds to torque, speed and power mode, and is connected to the switching cabinet;

[0012] One output end of the switching cabinet is connected to the motor through a junction box; the other output end is connected to the filter cabinet to filter the output power of the second inverter cabinet;

[0013] The output end of the filter cabinet is connected to a multi-tap transformer to provide different levels of power to the test piece when doing power supply experiments;

[0014] The multi-tap transformer is connected to the starter cabinet;

[0015] The starter cabinet is connected to the frequency converter via a junction box;

[0016] The frequency converter is connected to the motor via a junction box.

[0017] Furthermore, the detection system is composed of a detection unit and a PC end; the detection unit is cooperatively connected with the PC end, that is, the detection unit runs on the PC end.

[0018] Furthermore, a protection system is added to the detection system; the protection system is composed of a temperature protection system and a load fluctuation protection system; the temperature protection system is connected to the load fluctuation protection system and performs data exchange.

[0019] Furthermore, the temperature protection system is composed of a temperature sensor, a temperature acquisition module and a PLC control system; the temperature sensor, the temperature acquisition module and the PLC control system are connected in sequence; the temperature sensor is used to sense the temperature of the equipment, and collects data through the temperature acquisition module and transmits it to the PLC control system. If the over-temperature situation is reached, the PLC control system stops the operation of the equipment.

[0020] Furthermore, the load fluctuation protection system is composed of a torque speed sensor, a torque meter and a PLC control system; the torque speed sensor, the torque meter and the PLC control system are connected in sequence; the torque speed sensor and the torque meter are used to detect the torque change of the equipment. If the load fluctuation of the equipment is too high during operation, the PLC control system will stop the operation of the equipment.

[0021] The loading detection system of the transmission test bench provided by the present invention can be operated without manual intervention, thereby reducing the probability of errors caused by manual operation and improving work efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0023] Figure 1 It is the structure diagram of the transmission system given in this example;

[0024] Figure 2 This is a schematic diagram of the load fluctuation and temperature detection structure in this example.

[0025] The following is a description of the components in the accompanying drawings:

[0026] 101. Incoming power supply 103. Transformer 104. Incoming switch cabinet 105. Rectifier cabinet 106. First inverter cabinet 107. Second inverter cabinet 108. First junction box 109. Loading frequency conversion motor 110. Switching cabinet 111. Second junction box 112. Frequency conversion motor 113. Filter cabinet 114. Multi-tap transformer 115. Low-voltage starting cabinet 116. High-voltage starting cabinet 117. Low-voltage junction box 118. High-voltage junction box 119. First inverter 120. Second inverter 121. Second inverter junction box 122. First inverter junction box 123. Test motor 310. Temperature sensor 320. Torque and speed sensor 330. Torque meter 340. PLC control system. DETAILED DESCRIPTION

[0027] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further described below with reference to specific diagrams.

[0028] The present invention provides a transmission test bench loading detection system, which mainly includes a transmission system and a detection system.

[0029] See also Figure 1 , which is a transmission system structure diagram given in this example. As can be seen from the figure, the 10kV incoming power supply 101 is connected to the transformer 103, and the 10KV incoming power supply 101 outputs 1140V power after passing through the transformer 103, which is the incoming power supply for the entire transmission system 100.

[0030] The transformer 103 is connected to the incoming switch cabinet 104. The incoming switch cabinet 104 after the 1140V output by the transformer 103 is the main distribution switch of the transmission system 100, which is used to close or disconnect the power supply.

[0031] The transmission system inverter in this solution uses one rectifier cabinet 105 and two inverter cabinets; the rectifier cabinet 105 is a pulse rectifier unit cabinet, and the two currents output are respectively connected to two inverter cabinets, namely the first inverter cabinet 106 and the second inverter cabinet 107. Among them, the first inverter cabinet 106 corresponds to the torque and speed mode, and is connected to the 1140V loading frequency conversion motor 109 through the first junction box 108; the second inverter cabinet 107 corresponds to the torque, speed and power mode, and is connected to the switching cabinet 110.

[0032] The output end of the switch cabinet 110 is connected to the drive frequency conversion motor 112 through the second junction box 111; the other single output side is connected to the filter cabinet 113 to filter the output power of the second inverter cabinet 107, reducing the harmonics to less than 4%, meeting the national standard requirements; the switch cabinet 110 cooperates with the second inverter cabinet 107 to switch the torque speed mode and power mode to achieve the switching of the main circuit. When the motor is doing loading or dragging experiments, it mainly does the reducer, coupler, and brake experiments; it can also be switched to the filter cabinet 113 for power supply experiments, mainly including inverters, soft starters, and motor experiments.

[0033] Furthermore, the output end of the filter cabinet 113 is connected to a multi-tap transformer 114, and the multi-tap transformer 114 is mainly used to provide different levels of power to the test piece when doing a power supply experiment.

[0034] In this scheme, the output voltages are 660V, 1140V, 3.3V, 6KV, and 10KV respectively; 660V and 1140V are connected to the low-voltage starting cabinet 115, the low-voltage starting cabinet 115 is connected to the first inverter 119 through the low-voltage junction box 117, and the other end of the inverter is connected to the test motor 123 through the inverter junction box 122, and they cooperate with each other to conduct experiments on low-voltage equipment.

[0035] 3.3V, 6KV and 10KV are connected to the high-voltage starting cabinet 116, the high-voltage starting cabinet 116 is connected to the second inverter 120 through the high-voltage junction box 118, and the other end of the second inverter 120 is connected to the test motor 123 through the inverter junction box 121, which cooperate with each other to conduct experiments on high-voltage equipment.

[0036] Among them, the high and low voltage starting cabinets are used to realize the startup control and protection of the equipment; the high and low voltage junction boxes are mainly used to facilitate on-site wiring needs.

[0037] The detection system is composed of a PC and a detection unit. The data system displayed on the PC includes a power system, an automatic loading detection system and an automatic loading detection operating system.

[0038] The power system is the transmission system mentioned above, and the detection system displays the data collected by each detection unit through the PC.

[0039] Furthermore, the automatic loading monitoring system is mainly used to display whether the reducer test ready signal is ready. If the automatic detection system cannot be started, it can be checked which link is not set up properly.

[0040] The reducer no-load test is ready, the reducer efficiency test is ready, the reducer temperature rise test is ready, the reducer overload test is ready, and the coupler test is ready. The above modules are displayed independently on the display screen. If the automatic monitoring system cannot be started, it can be checked in time which link is not set up properly.

[0041] Furthermore, since automatic detection involves many links, a monitoring screen is needed to realize operation and indication, including automatic detection of reducer and automatic detection of coupling. Each module corresponds to the detection link, and its data distribution is concise and clear. This system can convey commands to the transmission system to realize various operations and switch at any time. At the same time, all the start-up processes of all reducer tests and the test processes can be displayed.

[0042] Secondly, this solution also adds protection measures in the detection system:

[0043] (1) Over-temperature protection:

[0044] like Figure 2 ,Over-temperature protection realizes over-temperature protection during automatic loading by monitoring the temperature rise of the tested equipment.

[0045] It is composed of a temperature sensor 310, a temperature acquisition module and a PLC control system 340, which are connected in sequence; the temperature sensor 310 is used to sense the temperature of the equipment, and collects data through the temperature acquisition module and transmits it to the PLC control system 340. If the temperature exceeds the limit, the PLC control system 340 stops the operation of the equipment.

[0046] If the reducer oil temperature exceeds 95 degrees and lasts for 1 second, the test bench will issue an over-temperature alarm. If the reducer oil temperature exceeds 100 degrees and lasts for 1 second, the test bench will report an over-temperature fault, stop the loading motor, and after unloading, stop the drive motor and check the fault. Among them, the alarm temperature and fault temperature values ​​can be set manually, and the temperature protection has a switch button.

[0047] (2) Load fluctuation protection:

[0048] like Figure 2 The load fluctuation protection system shown in the figure monitors the torque change of the tested equipment and stops loading the motor once the load fluctuation exceeds the set protection value during the automatic loading process.

[0049] It consists of a torque speed sensor 320, a torque meter 330 and a PLC control system 340, which are connected in sequence; the torque speed sensor 320 and the torque meter 330 are used to detect the torque change of the equipment. If the load fluctuation of the equipment is too high during operation, the PLC control system 340 will stop the operation of the equipment.

[0050] After the inverters on the loading side and the driving side reach a steady state, load fluctuations occur, and the load fluctuation value can be set. If the load fluctuation exceeds the set value and lasts for 10 seconds, it is determined that the test piece has a problem and a fault has formed, and the drive equipment is unloaded and stopped. At the same time, the duration can be set.

[0051] The following example illustrates the working process of this solution. It should be noted that the following content is only a specific application example of this solution and does not constitute a limitation on this solution.

[0052] First, the 10KV incoming power supply 101 supplies power through the transformer 103 and outputs 1140V power to supply power to the entire transmission system 100.

[0053] The incoming switch cabinet 104 after the 1140V output by the transformer 103 is the main distribution switch of the transmission system 100, which is used to close or disconnect the power supply.

[0054] Secondly, the first inverter cabinet 106 is connected to the 1140V loading frequency conversion motor 109 through the first junction box 108; the second inverter cabinet 107 is connected to the switching cabinet 110.

[0055] One output end of the switching cabinet 110 is connected to the drive variable frequency motor 112 through the second junction box 111; the other single output side is connected to the filter cabinet 113 to filter the output power of the second inverter cabinet 107 to less than 4%, meeting the national standard requirements.

[0056] The output end of the filter cabinet 113 is connected to a multi-tap transformer 114, and the output voltages are 660V, 1140V, 3.3V, 6KV, and 10KV respectively; among them, 660V and 1140V are connected to a low-voltage starting cabinet 115, and the low-voltage starting cabinet 115 is connected to a first inverter 119 through a low-voltage junction box 117, and the other end of the inverter is connected to a test motor 123 through a converter junction box 122, and they cooperate with each other to conduct experiments on low-voltage equipment.

[0057] 3.3V, 6KV and 10KV are connected to the high-voltage starting cabinet 116, the high-voltage starting cabinet 116 is connected to the second inverter 120 through the high-voltage junction box 118, and the other end of the second inverter 120 is connected to the test motor 123 through the inverter junction box 121, which cooperate with each other to conduct experiments on high-voltage equipment.

[0058] The following takes no-load test, efficiency test, temperature rise test and overload test as examples:

[0059] No-load test: First, run the monitoring system and the test system, power on the instrument, select the reducer test standard "MT / T148", select "no-load test" for the control software, select "reducer" for the test piece, set the second inverter cabinet 107 to speed mode; select "automatic detection" for the control mode, set the "reducer power" of the test piece, and set the "speed setting value" of the second inverter cabinet 107. Set the "acceleration and deceleration time". Set the "maximum and minimum speed limit values", and press the "start button" to start the no-load test.

[0060] The no-load test detection process is as follows: start the second inverter cabinet 107; delay 3s to start the inverter rectifier unit, charge to about 1700V and close the incoming cabinet contactor, and close the incoming cabinet contactor; delay 3s to start the second inverter cabinet 107; when the motor speed reaches the set speed, send a no-load test start sampling signal to the test system, and collect 3 groups of torque, speed, power, efficiency, and temperature data every 15 minutes; run for 1h1m or return the no-load test completion sampling signal from the test system, stop the main motor (inverter 2), delay stopping the auxiliary equipment and the inverter rectifier unit; the no-load test is completed.

[0061] Efficiency experiment: First, run the monitoring system and the test system, and power on the instrument. Select "efficiency experiment" for the control system, "reducer" for the test piece, and "automatic detection" for the control mode. Set the second inverter cabinet 107 to speed mode; set the "speed setting value" of the second inverter cabinet 107. Set the first inverter cabinet 106 to torque mode, and set the torque setting value of the first inverter cabinet 106 to 0. Set the "reducer power" of the test piece, set the "acceleration and deceleration time", and the "maximum and minimum speed limit values". Press the "start button" to start the efficiency experiment.

[0062] The efficiency test process is as follows: start the first inverter cabinet 106 and the second inverter cabinet 107 for 1s; delay 3s to start the inverter rectifier unit, charge to about 1700V and close the incoming cabinet contactor; close the incoming cabinet contactor, delay 3s to start the second inverter cabinet 107; the motor speed reaches the set speed, delay 3s to send a start signal to the first inverter cabinet 106; delay 3s to set the torque set value of the first inverter cabinet 106 to 25% of the rated power, after the speed stabilizes, delay 3s to send the efficiency experiment first inverter cabinet 106 start sampling signal to the test system, collect 3 groups of torque, speed, power, efficiency, and temperature data every 15 minutes; run for 1h1m or return from the test system to the efficiency experiment first inverter cabinet 106 to complete the sampling signal; detect the efficiency experiment first inverter cabinet 106 complete sampling signal, delay 3s to set the first inverter cabinet 106 torque set value to 50% of the rated power, after the speed stabilizes , delay 3s to send the efficiency experiment second inverter cabinet 107 start sampling signal to the test system, collect 3 groups of torque, speed, power, efficiency, and temperature data every 15 minutes; run for 1h1m or return the efficiency experiment second inverter cabinet 107 completion sampling signal from the test system; detect the efficiency experiment second inverter cabinet 107 completion sampling signal, delay 3s to set the first inverter cabinet 106 torque given value to 75% of the rated power, after the speed stabilizes, delay 3s to send the efficiency experiment No. 3 start sampling signal to the test system, collect 3 groups of torque, speed, power, efficiency, and temperature data every 15 minutes; run 1h1m or return the efficiency experiment No. 3 completion sampling signal from the test system; detect the efficiency experiment No. 3 completion sampling signal delay 3s to stop the main motor (first inverter), delay 5m to stop the second inverter cabinet 107 inverter, delay 10 to stop the auxiliary equipment and the inverter rectifier unit; the efficiency experiment is completed.

[0063] Temperature rise test: Run the monitoring system and the test system, and power on the instrument. Select "temperature rise test" for the control system, select "reducer" for the test piece, select "automatic detection" for the control mode, and set the "reducer power" of the test piece; set the second inverter cabinet 107 to speed mode, and set the "speed setting value" of the second inverter cabinet 107. Set the first inverter cabinet 106 to torque mode, and set the torque setting value of the first inverter cabinet 106 to 0. Set the "acceleration and deceleration time" and "maximum and minimum speed limit values". Press the "start button" to start the temperature rise test.

[0064] The temperature rise test detection process is as follows: start the first inverter cabinet 106 and the second inverter cabinet 107; delay 3s to start the inverter rectifier unit, charge to about 1700V and close the incoming cabinet contactor; close the incoming cabinet contactor, delay 3s to start the second inverter cabinet 107; the motor speed reaches the set speed, delay 3s to send a start signal to the first inverter cabinet 106; delay 3s to set the torque set value of the first inverter cabinet 106 to the rated load, and after the speed stabilizes, delay 3s to send a temperature rise test start signal to the test system Sampling signal, collect 3 groups of torque, speed, power, efficiency and temperature data every 15 minutes; when over-temperature fault occurs during operation or the temperature rise experiment is completed, the sampling signal is returned from the test system; when the temperature rise experiment is completed, the sampling signal is delayed for 3s to stop the main motor (first inverter cabinet), delayed for 5s to stop the second inverter cabinet 107, and delayed for 10s to stop the auxiliary equipment and the inverter rectifier unit; the temperature rise experiment time is uncertain in the temperature rise experiment, and there are two results in the end: one is that the experiment is qualified and thermal equilibrium is reached, and the other is that the experiment fails and over-temperature action is taken.

[0065] Overload test: First, run the monitoring system and the test system, and power on the instrument. Set the control system to "overload test", select "reducer" for the test piece, select "automatic detection" for the control mode, and set the "reducer power" of the test piece; automatically set the second inverter cabinet 107 to speed mode, and set the "speed setting value" of the second inverter cabinet 107. Set the first inverter cabinet 106 to torque mode, and set the torque setting value of the first inverter cabinet 106 to 0. Set the "acceleration and deceleration time", "maximum and minimum speed limit values", and press the "start button" to start the overload test.

[0066] The overload test detection process is as follows: start the first inverter cabinet 106 and the second inverter cabinet 107; delay 3s to start the inverter rectifier unit, charge to about 1700V and close the incoming cabinet contactor; close the incoming cabinet contactor, delay 3s to start the second inverter cabinet 107; the motor speed reaches the set speed, and delay 3s to send a start signal to the first inverter cabinet 106; delay 3s to set the torque set value of the first inverter cabinet 106 to 125% of the rated load, and after the speed stabilizes, delay 3s to send an overload test start sampling signal to the test system; run for 11 minutes or return the overload test completion sampling signal from the test system; collect 3 groups of torque, speed, power, efficiency, and temperature data every 5 minutes; delay 3s after the detection completion sampling signal to stop the main motor, delay stopping the auxiliary equipment and the inverter rectifier unit; the overload test is completed.

[0067] The loading detection system of a transmission test bench formed by the above scheme has the following advantages in its specific application:

[0068] (1) It realizes efficient loading and testing of no-load test, efficiency test, temperature rise test and overload test of mechanical equipment;

[0069] (2) Reduce operator errors and operational difficulties;

[0070] (3) Over-temperature protection and abnormal fluctuation protection have been added to protect the normal operation of the machine.

[0071] The above shows and describes the basic principles, main features and advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A loading detection system for a transmission test bench, characterized in that: It includes a transmission system and a detection system; the transmission system is composed of an incoming power supply, a transformer, an incoming switch cabinet, a rectifier cabinet, a first inverter cabinet, a second inverter cabinet, a switching cabinet, a filter cabinet, a high-voltage starter cabinet, a low-voltage starter cabinet, a first frequency converter, a second frequency converter, a motor and a tested motor; The incoming power supply is connected to the transformer, and the incoming power supply is supplied to the entire transmission system after passing through the transformer; The transformer is connected to the incoming switch cabinet, which is the main distribution switch of the transmission system and is used to close or disconnect the power supply; The two currents output by the rectifier cabinet are connected to the first inverter cabinet and the second inverter cabinet respectively; The first inverter cabinet corresponds to the torque and speed mode and is connected to the loading variable frequency motor through the first junction box; the second inverter cabinet corresponds to the torque, speed and power mode and is connected to the switching cabinet; One output end of the switching cabinet is connected to drive the variable frequency motor through the second junction box; the other single output side is connected to the filter cabinet, which is used to filter the output power of the second inverter cabinet and reduce the harmonics to less than 4%. The switching cabinet can cooperate with the second inverter cabinet to switch the torque speed mode and power mode to achieve the switching of the main circuit. When the motor is doing loading or dragging experiments, the reducer, coupler, and brake experiments are carried out; it can also switch to the filter cabinet for power supply experiments, and perform inverter, soft start and motor experiments; The output end of the filter cabinet is respectively connected to the high-voltage starting cabinet and the low-voltage starting cabinet; the high-voltage starting cabinet and the low-voltage starting cabinet are respectively connected to the first frequency converter and the second frequency converter; the first frequency converter is connected to the test motor and cooperates with each other to perform experiments on low-voltage equipment, and the second frequency converter is connected to the test motor and cooperates with each other to perform experiments on high-voltage equipment.

2. A transmission test bench loading detection system according to claim 1, characterized in that: The detection system is composed of a detection unit and a PC end; the detection unit is connected with the PC end, that is, the detection unit runs on the PC end.

3. The loading detection system of a transmission test bench according to claim 1, characterized in that: A protection system is added to the detection system; the protection system is composed of a temperature protection system and a load fluctuation protection system; the temperature protection system is connected to the load fluctuation protection system and performs data exchange.

4. A loading detection system for a transmission test bench according to claim 3, characterized in that: The temperature protection system is composed of a temperature sensor, a temperature acquisition module and a PLC control system; the temperature sensor, the temperature acquisition module and the PLC control system are connected in sequence; the temperature sensor is used to sense the temperature of the equipment, and collects data through the temperature acquisition module and transmits it to the PLC control system. If the over-temperature situation is reached, the PLC control system stops the operation of the equipment.

5. The loading detection system of a transmission test bench according to claim 3, characterized in that: The load fluctuation protection system is composed of a torque speed sensor, a torque meter and a PLC control system; the torque speed sensor, the torque meter and the PLC control system are connected in sequence; the torque speed sensor and the torque meter are used to detect the torque change of the equipment. If the load fluctuation of the equipment is too high during operation, the PLC control system will stop the operation of the equipment.

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