A simulation system for shearing process of spent fuel rods

Abstract

The present invention provides a spent fuel rod shearing process simulation system, comprising an operation console, a PC computer with a graphic workstation configuration and a programmable controller PLC, wherein each operation element and a signal light display device on the operation console are connected to the programmable controller PLC, a virtual simulation unit is provided in the PC computer, and the programmable controller PLC sends and receives signals from the virtual simulation unit. The spent fuel rod shearing process simulation system provided by the present invention has a short training cycle, high efficiency, and does not have any safety risks, and well makes up for the shortcomings of shearing machine operation training.

Description

Technical Field

[0001] The invention relates to the technical field of spent fuel rod simulation, and in particular to a spent fuel rod shearing process simulation system. Background Art

[0002] The spent fuel rod cutting site is radioactive and confined, so operators cannot observe the site environment closely and learn the spent fuel treatment process. In addition, regulations require operators to master the process before they can take up their posts, so the current training methods have a long cycle and low efficiency. Summary of the invention

[0003] The purpose of the present invention is to overcome the defects described in the prior art, thereby providing a spent fuel rod shearing process simulation system, which has a short training cycle, high efficiency, and no safety risks, and well makes up for the shortcomings of shearing machine operation training.

[0004] In order to achieve the above object, the present invention provides the following technical solutions:

[0005] A spent fuel rod shearing process simulation system comprises an operation console, a PC with a graphic workstation configuration and a programmable controller (PLC), wherein each operation element and a signal light display device on the operation console are connected to the programmable controller (PLC), a virtual simulation unit is arranged in the PC, and the programmable controller (PLC) sends and receives signals from the virtual simulation unit.

[0006] Furthermore, the programmable controller PLC comprises:

[0007] Periodically call program blocks to implement cyclic calls to related functions and subroutine blocks;

[0008] An initialization program block is used to initialize the controller when the programmable controller PLC is warm started;

[0009] The initialization assignment module is used to initialize relevant parameters under specific conditions.

[0010] Furthermore, the programmable controller PLC also includes:

[0011] Parameter interlocking module, used for interlocking control and logical operation of automatic or manual cutting parameters;

[0012] Automatic loading module, used to perform automatic loading process logic control;

[0013] Automatic shearing module, used for executing automatic shearing process logic control;

[0014] Manual operation module, used to perform logic control of manual loading and shearing;

[0015] The inching operation module is used for inching operation control. When receiving the physical signal input on the operation console, the virtual device moves and acts without any interlocking.

[0016] Furthermore, the programmable controller PLC sends the calculation result to the virtual simulation unit in the form of an output point signal, the virtual simulation unit receives the output point signal of the programmable controller PLC, controls the relevant actions of the shearing device in the virtual simulation unit, and the virtual simulation unit returns the status information of the device.

[0017] Furthermore, the virtual simulation unit includes:

[0018] The student-side module includes a shearing machine process 3D simulation computer system, which is used to display the equipment operation status and provide feedback on the equipment's action and status information.

[0019] The scene-side module includes a large-screen projection system that displays the scene environment and device models through the projection screen.

[0020] The instructor-side module includes an instructor control system and a 3D simulation terminal system. The instructor control system is used for any working condition setting and fault setting, and the 3D simulation terminal system synchronizes the operating status of the trainee-side equipment.

[0021] Furthermore, the virtual simulation unit includes:

[0022] The grid cutting function module is used to realize the special effects of the fuel rods being squeezed and deformed during the shearing process, the special effects of the fuel rods being cut by the shearing machine head, and the special effects of sparks and dust during the cutting process;

[0023] A data interaction function module is used to realize real-time and efficient data transmission between the virtual simulation unit and the programmable controller PLC;

[0024] The knife-jumping function module is used to enable the entire system to switch to the working condition corresponding to the specified number of shear knives at will, including the working condition of any number of knives in the normal shearing stage and the final shearing stage.

[0025] Furthermore, the virtual simulation unit also includes a fault insertion function module, which includes a fault logic program in the virtual simulation unit and the programmable controller PLC, and is used for inserting several fault conditions that often occur in actual shearing operations and logic control after the fault is eliminated.

[0026] Compared with the prior art, the spent fuel rod shearing process simulation system provided by the present invention has the following beneficial effects:

[0027] The spent fuel rod shearing process simulation system provided by the present invention realizes the reproduction of the working scene on the computer display screen through three-dimensional simulation technology. The industrial control program of the system is designed and programmed completely according to the operating process logic of the shearing machine in actual working conditions, and the knife jump function and fault insertion function are added at the same time, which greatly improves the training efficiency and has strong pertinence and operability. The shearing operation training using the simulation system is not limited by the operating status of the unit, and there is no safety risk, which makes up for the shortcomings of shearing machine operation training. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0029] Figure 1 It is the system principle framework diagram of the present invention;

[0030] Figure 2 It is a principle framework diagram of the knife jumping function of the present invention. DETAILED DESCRIPTION

[0031] Although the spent fuel rod shearing process simulation system of the present invention can be implemented in a variety of different ways, this article will describe the exemplary embodiments in detail in conjunction with the drawings, without intending to limit the protection scope of the present invention to the exemplary embodiments. Therefore, in essence, the drawings and the description of the specific embodiments should be considered to be used to illustrate rather than limit the present invention.

[0032] The following is further explained in detail through specific implementation methods.

[0033] like Figure 1 and Figure 2As shown, the present invention provides a spent fuel rod shearing simulation system, which is composed of an operation console, a PC computer with a graphic workstation configuration and a programmable controller PLC, wherein the operation console is designed 1:1 according to the physical console at the spent fuel rod shearing site, and each operation element and a signal light display device on the operation console are connected to the programmable controller PLC, and the operation console sends switch signals, buttons and other operation signals to the programmable controller PLC, and the programmable controller PLC controls the high and low potentials of the output points and the signal lights on the console according to the results of the logic operation. A virtual simulation unit and OPC software are provided in the PC computer, and the OPC software is used to realize the data interaction between the programmable controller PLC and the virtual simulation unit in the PC computer, and the virtual simulation unit transmits the state information of the shearing device to the programmable controller PLC for logic chain operation processing, and the programmable controller PLC sends the operation result to the virtual simulation unit as an output point signal; the virtual simulation unit in the PC computer receives the output point signal of the programmable controller PLC, controls the relevant actions of the shearing device in the virtual simulation unit, and the virtual simulation unit returns the state information of the device.

[0034] The spent fuel shearing process simulation system, wherein the programmable controller PLC includes the following functional modules:

[0035] Periodically call program blocks to implement cyclic calls to related functions and subroutine blocks;

[0036] Initialization program block, which performs controller initialization when the programmable controller PLC is warm started;

[0037] Initialization assignment module, used to initialize relevant parameters under specific conditions;

[0038] Parameter interlocking module, used for interlocking control and logical operation of automatic or manual cutting parameters;

[0039] Automatic loading module, used to perform automatic loading process logic control;

[0040] Automatic shearing module, used for executing automatic shearing process logic control;

[0041] Manual operation module, used to perform logic control of manual loading and shearing;

[0042] The inching operation module is used for inching operation control. When the physical signal input on the operating table is received, the virtual device moves and acts without any interlocking.

[0043] In addition, the virtual simulation unit in the PC computer includes the following functional modules:

[0044] The student-side module includes a shearing machine process 3D simulation computer system, which is used to feedback the equipment status information and display the equipment operation status.

[0045] The scene-side module includes a large-screen projection system that displays the scene environment and device models through the projection screen.

[0046] The instructor-side module includes an instructor control system and a 3D simulation terminal system. The former is used for working condition setting and fault setting, and the latter synchronizes the operating status of the trainee-side equipment.

[0047] The mesh cutting function module includes mesh deformation and segmentation algorithms, which are used to achieve the special effects of fuel rods being squeezed and deformed during the shearing process, the special effects of fuel rods being cut by the shearing machine head, and the special effects of sparks and dust during the cutting process;

[0048] Data interaction function module, used to realize real-time and efficient data transmission between virtual simulation unit and programmable controller PLC;

[0049] The knife-jumping function module is used to enable the entire system to switch to the state corresponding to the specified number of shear knives at will, including the working state of any number of knives in the normal shearing stage and the final shearing stage.

[0050] The fault insertion function module includes the fault logic program in the virtual simulation unit and the programmable controller PLC, which is used to insert several fault conditions that often occur in actual shearing operations and the logical control after the fault is eliminated.

[0051] Among them, Figure 1 As shown, the student-side module, scene-side module and instructor-side module will be described in detail below.

[0052] Student-side module: The shearing machine process 3D simulation computer system uses the communication module to communicate with the process control system; it is used to simulate the actions of the shearing machine equipment and feedback equipment information, as well as the simulation motion models of other equipment; at the same time, it can simulate various working scenarios of the shearing equipment, create abnormal and faulty operating conditions, and receive operating instructions from the process control system; it presents the intuitive operating conditions of the shearing equipment to the operator in the form of 3D simulation graphics; and uses the blur filter special effects to restore the on-site camera screen effect.

[0053] Scene-end module: The large-screen projection system is connected to the shearing machine process 3D simulation computer system through an interface transfer module; the environmental scene where the shearing equipment is located is projected onto the large screen through a projector, including the entire shearing plant's internal facility layout, lighting and environment rendering effects, and the corresponding three-dimensional structural model of the equipment in the shearing system; interactive navigation operations can be performed in the simulation scene through the terminal system mouse and keyboard to enhance the operator's experience.

[0054] Instructor station module: The instructor control system is connected to the simulation process 3D simulation system through the interface transfer module; it is mainly used to set various simulation scenarios, send abnormal working conditions, set the working status of fuel rods and shearing machines, etc., and receive and record operation data during the training process; the 3D simulation terminal system is connected to the simulation process 3D simulation system through the interface transfer module, which is used to synchronously display the 3D simulation operation screen of the shearing equipment for the instructor to view and monitor the operation of the trainee end.

[0055] Interface transfer module: As the interface transfer between the OPC client and the virtual simulation unit, the PLC transmits the data to the OPC client, and the OPC client forwards it to the interface transfer module, which sends the data to the student end, the instructor end and the display end at the same time through the broadcast method in the local area network.

[0056] Communication module: Use Kepserver software as the OPC server to realize the communication between PLC and OPC server. Establish the socket server and OPC client of the interface transfer module, establish the socket client in the virtual scene unit, realize the communication between the virtual scene unit and OPC client, and finally realize the data interaction between PLC and virtual scene unit.

[0057] Knife jump module: When performing a knife jump operation, enter the knife jump number n on the touch screen HMI, and the entire shear system will be switched to the initial state of the nth knife through the PLC program. The knife jump module includes:

[0058] (1) Transmission of tool jump parameters

[0059] Input the number of tool jumps n and pass it to the virtual simulation unit.

[0060] (2) Determine the jumper position

[0061] When jumping to the nth cut, the position where the tool holder will cut the component is calculated based on the cutting process and cutting related parameters.

[0062] Taking the jump to the normal shearing stage as an example, the calculation formula is as follows:

[0063] C8=CC0+CC1+CC2+(n-2)×CC3

[0064] Where C8: the distance the component descends at the nth cut;

[0065] CC0: initial stroke position of the component before shearing, fixed value;

[0066] CC1: First cutting length, fixed value;

[0067] CC2: The second cutting length, fixed value;

[0068] CC3: The cutting length of each knife during the normal cutting stage, a fixed value.

[0069] The component drop distance C8 is calculated based on relevant parameters, and the nth knife shearing position can be determined.

[0070] (3) Component cutting operation

[0071] Determine the cutting position after the jump cut, the part above the position is not cut, and the part below the position is cut. According to the above mesh cutting algorithm, the cut part is destroyed.

[0072] (4) Initialization of state parameters in the scene

[0073] After the knife jumps, the virtual simulation unit initializes the state parameters of the field equipment corresponding to the knife, and transmits the state parameters and the component drop distance C8 to the PLC.

[0074] (5) Program control parameter initialization

[0075] When the virtual simulation unit transmits the component descent distance value and the knife jump number n to the PLC, the control parameters corresponding to the knife number are initialized according to the PLC knife jump program.

[0076] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any changes or substitutions that can be easily thought of by a person skilled in the art within the technical scope disclosed by the present invention should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A spent fuel rod shearing process simulation system, characterized in that: It includes an operation console, a PC computer with a graphic workstation configuration and a programmable controller PLC, wherein each operation element and a signal light display device on the operation console are connected to the programmable controller PLC, a virtual simulation unit is provided in the PC computer, and the programmable controller PLC sends and receives signals from the virtual simulation unit; The virtual simulation unit comprises: The grid cutting function module is used to realize the special effects of the fuel rods being squeezed and deformed during the shearing process, the special effects of the fuel rods being cut by the shearing machine head, and the special effects of sparks and dust during the cutting process; A data interaction function module is used to realize real-time and efficient data transmission between the virtual simulation unit and the programmable controller PLC; The knife-jumping function module is used to allow the entire system to switch to the state corresponding to the specified number of shear knives at will, including the working state of any number of knives in the normal shearing stage and the final shearing stage.

2. The spent fuel rod shearing process simulation system according to claim 1, characterized in that: The programmable controller PLC comprises: Periodically call program blocks to implement cyclic calls to related functions and subroutine blocks; An initialization program block is used to initialize the controller when the programmable controller PLC is warm started; The initialization assignment module is used to initialize relevant parameters under specific conditions.

3. The spent fuel rod shearing process simulation system according to claim 2, characterized in that: The programmable controller PLC also includes: Parameter interlocking module, used for interlocking control and logical operation of automatic or manual cutting parameters; Automatic loading module, used to perform automatic loading process logic control; Automatic shearing module, used for executing automatic shearing process logic control; Manual operation module, used to perform logic control of manual loading and shearing; The inching operation module is used for inching operation control. When receiving the physical signal input on the operation console, the virtual device moves and acts without any interlocking.

4. The spent fuel rod shearing process simulation system according to claim 1, characterized in that: The programmable controller PLC sends the calculation result to the virtual simulation unit in the form of an output point signal. The virtual simulation unit receives the output point signal of the programmable controller PLC, controls the relevant actions of the shearing device in the virtual simulation unit, and returns the status information of the device.

5. The spent fuel rod shearing process simulation system according to claim 1, characterized in that: The virtual simulation unit comprises: The student module includes a shearing machine process 3D simulation computer system, which is used to display the equipment operation status and feedback the equipment's action and status information; The scene-side module includes a large-screen projection system that displays the scene environment and device models through the projection screen; The instructor-side module includes an instructor control system and a 3D simulation terminal system. The instructor control system is used for arbitrary working condition settings and fault settings, and the 3D simulation terminal system synchronizes the operating status of the trainee-side equipment.

6. The spent fuel rod shearing process simulation system according to claim 1, characterized in that: The virtual simulation unit also includes a fault insertion function module, which includes a fault logic program in the virtual simulation unit and a programmable controller PLC, and is used for inserting several fault conditions that often occur in actual shearing operations and for logic control after the faults are eliminated.

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