Lubricating oil system debugging method based on digital twinning

Abstract

This invention discloses a method for debugging a lubricating oil system based on digital twins, comprising the following steps: 1) Constructing a simulation model of the lubricating oil system and equipment by defining a lubricating oil system equipment model library; 2) The online model receives real-time operating data of the physical lubricating oil system collected by sensors, transmits the online measured data to the simulation model to drive simulation calculation, and transmits the calculation results to the demonstration model for simulation animation display; 3) Based on the lubricating oil user flow requirements under different pre-given operating conditions, and based on virtual-real fusion simulation, the action parameters of each actuator of the lubricating oil system are calculated through offline model tuning and transmitted to the control system as virtual debugging signals; 4) The physical lubricating oil system receives the control signals from the control system to adjust and control the operation of the physical lubricating oil system. This invention, by constructing a high-precision lubricating oil system model and using digital twin-based virtual debugging technology for lubricating oil systems, can be used for efficient debugging, accurate analysis, and virtual verification of physical systems.

Description

Technical Field

[0001] This invention relates to digital twin technology, and more particularly to a method for debugging a lubricating oil system based on digital twins. Background Technology

[0002] The lubrication system in a power system needs to meet the lubrication needs of multiple users with varying lubrication characteristics under multiple operating conditions. Furthermore, the propulsion turbine unit accounts for a significant portion (approximately 80%) of the lubrication oil demand among all users, and changes in lubrication flow rate during turbine operation will significantly disrupt other lubrication-consuming equipment. Due to the characteristics of lubrication users in this new power system, ensuring the inlet oil quantity and pressure for each user under varying operating conditions results in low efficiency, high cost, and long testing cycles for the lubrication system.

[0003] Meanwhile, the measurement points of the actual ship's lubricating oil system are limited, and flow meters are generally not set up. During the commissioning process, only the lubricating oil inlet pressure is used as the basis for commissioning, which limits the information that the commissioning personnel can obtain and is also one of the reasons for the low commissioning efficiency. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a lubricating oil system debugging method based on digital twin, which addresses the deficiencies in the prior art.

[0005] The technical solution adopted by this invention to solve its technical problem is: a lubricating oil system debugging method based on digital twin, comprising the following steps:

[0006] 1) By defining a lubricating oil system equipment model library, simulation models of lubricating oil systems and equipment are constructed; the simulation models of lubricating oil systems and equipment include online models and offline models;

[0007] 2) The online model receives real-time operating data of the physical lubricating oil system collected by sensors, transmits the online measured data to the simulation model to drive simulation calculation, and transmits the calculation results to the demonstration model for simulation animation display; the demonstration model is similar to the physical system at a 1:1 scale, and displays the physical status and key parameter information by numerically linking the equipment model and the system model.

[0008] The real-time operating data includes: lubricating oil system measurement signal parameters and lubricating oil system control signal parameters;

[0009] The lubricating oil system control signals include valve opening signals and pump speed signals;

[0010] 3) Based on the lubricating oil user flow requirements under different pre-given operating conditions, and using virtual-real fusion simulation, the action parameters of each actuator of the lubricating oil system are pre-tuned and calculated through an offline model and transmitted to the control system as virtual debugging signals; the action parameters include: the speed of the electric lubricating oil pump and the opening degree of each regulating valve;

[0011] The specific motion parameters of each actuator in the lubricating oil system are calculated and pre-tuned using an offline model, as follows:

[0012] 3.1) Calculate the parameters of the branch regulating valves based on the flow rate of each lubricating oil user to ensure that the flow rate of each lubricating oil user meets the requirements;

[0013] 3.2) Based on the target value of the main oil pressure, calculate the speed of the electric oil pump and the opening of the main oil pressure regulating valve to ensure that the main oil pressure meets the requirements;

[0014] 3.3) Iterate through steps 3.1 and 3.2 until the flow rate of each lubricating oil user and the pressure of the lubricating oil manifold meet the requirements. At this point, the system is in a steady state, and the pressure and flow rate of the lubricating oil manifold remain stable.

[0015] 3.4) Based on the lubricating oil main flow rate obtained in step 3.3), calculate the opening of the cooling water regulating valve to obtain the cooling water flow rate, so that the lubricating oil temperature after passing through the cooler meets the requirements of each user.

[0016] 4) The physical lubricating oil system receives control signals from the control system and adjusts and controls the operation of the physical lubricating oil system.

[0017] According to the above scheme, step 1) uses the unified multiphysics modeling language Modelica for modeling, as detailed below:

[0018] Based on the multi-physical quantity unified modeling language Modelica, a simulation model of the equipment is constructed, including the lubricating oil tank, lubricating oil pump, motor, overflow valve, filter, check valve, heat exchanger, heater, regulating valve, lubricating oil medium, pipeline model, and control module. The lubricating oil system model is then constructed based on the equipment simulation model.

[0019] The beneficial effects of this invention are:

[0020] This invention constructs a high-precision lubricating oil system model and utilizes digital twin-based virtual debugging technology for lubricating oil systems. This is of great significance for the refined debugging of lubricating oil systems, multi-objective optimization of equipment / systems, improvement of comprehensive performance, and partial replacement of tests. At the same time, based on digital twins, it constructs a collaborative interaction between the physical system and the twin model, realizing full-state perception of the physical system. This can be used to support key tasks such as efficient debugging, accurate analysis, and virtual verification of physical systems. Attached Figure Description

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the accompanying drawings:

[0022] Figure 1 This is a flowchart of a method according to an embodiment of the present invention;

[0023] Figure 2This is a schematic diagram of the working process of the lubricating oil system according to an embodiment of the present invention. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0025] like Figure 1 As shown, a method for debugging a lubricating oil system based on digital twins includes the following steps:

[0026] 1) Based on the Modelica language, a lubricating oil system model (including online and offline models) is constructed by defining a lubricating oil system equipment model library. Both the lubricating oil system equipment model library and the system model are verified using experimental data to ensure model accuracy. The offline and online models are digital twins of the physical system.

[0027] Based on virtual-real fusion simulation, the offline model pre-calibrates and calculates the action parameters of each actuator in the lubricating oil system (electric lubricating oil pump speed, regulating valve opening, etc.) and transmits them as virtual debugging signals to the control system, guiding the operation and decision-making of the test personnel during the test. The online model receives data collected from the physical system in real time, drives simulation calculations, and transmits the calculation results to the demonstration model for simulation animation display. Combining the physical system and the simulation model, the lubricating oil system achieves full-state perception and virtual debugging, guiding the operation and debugging of the physical test system.

[0028] The lubricating oil system consists of an electric lubricating oil pump, a magnetic filter, a main lubricating oil filter, a lubricating oil cooler, a circulating lubricating oil tank, regulating valves, and lubricating oil users. The specific workflow of the lubricating oil system is as follows: Figure 2 As shown, the electric lubricating oil pump draws lubricating oil from the circulating lubricating oil tank, filters it through a magnetic filter and the main lubricating oil filter, then cools it in the cooler and distributes it to various lubricating oil users through the lubricating oil manifold.

[0029] The following parameters need to be adjusted during the commissioning of the lubricating oil system:

[0030] 1) Adjust the speed of the electric lubricating oil pump and the opening of the main pipe pressure regulating valve to ensure that the pressure in the main lubricating oil pipe meets the requirements.

[0031] 2) At the same time, it is necessary to adjust the lubricating oil regulating valve in front of the user so that the inlet pressure and flow rate of each lubricating oil user meet the requirements under the three working conditions.

[0032] 3) Adjust the cooling water flow rate by using the cooling water regulating valve so that the lubricating oil temperature after passing through the cooler meets the requirements of each user.

[0033] This invention utilizes the unified multi-physical modeling language Modelica to construct simulation models of key equipment, including an oil tank, oil pump, motor, overflow valve, filter, check valve, heat exchanger, heater, regulating valve, lubricating oil medium, piping model, and control module. Based on these equipment models, a lubricating oil system model is constructed, effectively simulating the fluid, thermal, and control characteristics of the lubricating oil system. After correction using experimental data, the high-precision lubricating oil system simulation model built using Modelica exhibits a steady-state simulation error of <5% and a dynamic simulation error of <10%.

[0034] Based on a lubricating oil system equipment model library, both offline and online simulation models were constructed. The offline model is used for physical control interaction, transmitting operating condition tuning parameters to the control system. The online model is used to receive real-time data from the physical system, drive simulation calculations, and transmit the calculation results to the demonstration model for simulation animation display.

[0035] The data interface module and simulation software are both deployed in the simulator. Based on the Modbus / TCP protocol, the host computer of the control system transmits the measurement point data of the physical system to the simulator. The data interface software in the simulator converts the Modbus / TCP protocol data into general interface protocol data (based on UDP) and then transmits the data to the simulation software (online simulation model).

[0036] Data within the simulation software (offline simulation model) is also transmitted to the data interface software via the universal interface protocol (UDP), converted into Modbus / TCP data, and finally transmitted to the host computer of the control system.

[0037] 2) Based on virtual-real interaction, the online simulation model receives signals from all measuring points of the control system in real time, including control signals (pump speed, regulating valve opening) and measurement signals. It extracts the control signals to drive the simulation model and calculates the simulation parameters. The two-dimensional and three-dimensional models receive online simulation model data in real time and, through real-time data interaction, display all information about the lubricating oil system, achieving full-state monitoring of the lubricating oil system, understanding the system's operating status, and assisting test personnel in decision-making and judgment. Both two-dimensional and three-dimensional models can display all simulation data in real time. Taking the three-dimensional model as an example:

[0038] The 3D demonstration model is 1:1 similar to the physical system, and can display the physical state and key parameter information in detail. The 3D demonstration model receives calculation data from the simulation model in real time and drives the real-time information display of the model, displaying numerical data that correlates the equipment model and system model data. The specific effects and functions are shown below.

[0039] (1) Electric lubricating oil pump: speed, discharge pressure, flow rate.

[0040] (2) Lubricating oil cooler: cooling water flow rate, lubricating oil flow rate, lubricating oil inlet temperature, lubricating oil outlet temperature.

[0041] (3) Control valves: opening degree, flow rate, differential pressure. The default display shows pressure control valves. When you click on different control valves, the status and name of the control valve will be displayed automatically.

[0042] When a main device is clicked, its simulation calculation information will be displayed in real time. The displayed information includes:

[0043] Oil pump: speed, discharge pressure, flow rate;

[0044] Control valve: opening degree, pressure drop, flow rate;

[0045] Oil tank, liquid level, temperature;

[0046] Lubricating oil cooler: cooling water flow rate, inlet temperature, outlet temperature; lubricating oil flow rate, inlet temperature, outlet temperature.

[0047] Dynamic effect of lubricating oil movement: The lubricating oil flow effect in the 3D model is related to the actual lubricating oil flow rate. The greater the flow rate, the stronger the effect. When the lubricating oil flow rate is 0, the lubricating oil flow effect stops.

[0048] Color dynamic effect: The color of the lubricating oil is related to the temperature of the lubricating oil.

[0049] Oil tank animation effects: The oil level and temperature effects in the lubricating oil tank are driven in real time by simulation data.

[0050] All state parameters can be added or changed in the 3D model according to the experimental requirements.

[0051] During the experiment, the testers can obtain any data in real time, such as lubricating oil flow, lubricating oil temperature, and lubricating oil pressure, through two-dimensional or three-dimensional demonstration models, thereby gaining a full understanding of the physical system's state and using it to assist in test decision-making.

[0052] 3) During virtual commissioning, the offline simulation model calculates virtual commissioning signals such as the valve opening degree of each branch's set valve and the pump speed based on the oil usage requirements of each lubricating oil user. The offline simulation model transmits these virtual commissioning signals to the host computer on the control panel, which displays the virtual commissioning signals and other parameters through the virtual commissioning interface. On-site operators choose whether to adopt the virtual commissioning value based on the actual situation. If adopted, the physical test system receives the virtual commissioning signal, ensuring that the physical operating state matches the state of the simulation model, thus meeting the oil usage requirements of each lubricating oil user and achieving virtual commissioning of the physical system by the digital twin. Virtual commissioning through the digital twin effectively shortens the commissioning time during testing and improves testing efficiency.

[0053] The specific motion parameters of each actuator in the lubricating oil system are calculated and pre-tuned using an offline model, as follows:

[0054] 3.1) Calculate the parameters of the branch regulating valves based on the flow rate of each lubricating oil user to ensure that the flow rate of each lubricating oil user meets the requirements;

[0055] 3.2) Based on the target value of the main oil pressure, calculate the speed of the electric oil pump and the opening of the main oil pressure regulating valve to ensure that the main oil pressure meets the requirements;

[0056] 3.3) Iterate through steps 3.1 and 3.2 until the flow rate of each lubricating oil user and the pressure of the lubricating oil manifold meet the requirements. At this point, the system is in a steady state, and the pressure and flow rate of the lubricating oil manifold remain stable.

[0057] 3.4) Based on the lubricating oil main flow rate obtained in step 3.3), calculate the opening of the cooling water regulating valve to obtain the cooling water flow rate, so that the lubricating oil temperature after passing through the cooler meets the requirements of each user.

[0058] 4) The physical lubricating oil system receives control signals from the control system and adjusts and controls the operation of the physical lubricating oil system.

[0059] It should be understood that those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. A method for debugging a lubricating oil system based on digital twins, characterized in that, Includes the following steps: 1) By defining a lubricating oil system equipment model library, simulation models of lubricating oil systems and equipment are constructed; the simulation models of lubricating oil systems and equipment include online models and offline models; 2) The online model receives real-time operating data of the physical lubricating oil system collected by sensors, transmits the online measured data to the simulation model to drive simulation calculation, and transmits the calculation results to the demonstration model for simulation animation display; the demonstration model is 1:1 similar to the physical system, and displays the physical status and key parameter information by numerically linking the equipment model and the system model. The real-time operating data includes: lubricating oil system measurement signal parameters and lubricating oil system control signal parameters; The lubricating oil system control signals include valve opening signals and pump speed signals; 3) Based on the lubricating oil user flow requirements under different pre-given operating conditions, and using virtual-real fusion simulation, the action parameters of each actuator of the lubricating oil system are pre-tuned and calculated through an offline model and transmitted to the control system as virtual debugging signals; the action parameters include: the speed of the electric lubricating oil pump and the opening degree of each regulating valve; The specific motion parameters of each actuator in the lubricating oil system are calculated and pre-tuned using an offline model, as follows: 3.1) Calculate the parameters of the branch regulating valves based on the flow rate of each lubricating oil user to ensure that the flow rate of each lubricating oil user meets the requirements; 3.2) Based on the target value of the main oil pressure, calculate the speed of the electric oil pump and the opening of the main oil pressure regulating valve to ensure that the main oil pressure meets the requirements; 3.3) Iteration steps 3.1) and 3.2) ensure that the flow rate of each lubricating oil user and the pressure of the lubricating oil main pipe meet the requirements. At this time, the system is in steady state, and the pressure and flow rate of the lubricating oil main pipe remain stable. 3.4) Based on the lubricating oil main flow rate obtained in step 3.3), calculate the opening of the cooling water regulating valve to obtain the cooling water flow rate, so that the lubricating oil temperature after passing through the cooler meets the requirements of each user. 4) The physical lubricating oil system receives control signals from the control system and adjusts and controls the operation of the physical lubricating oil system.

2. The lubricating oil system debugging method based on digital twin according to claim 1, characterized in that, In step 1), the unified multiphysics modeling language Modelica is used for modeling, as detailed below: Based on the multi-physical quantity unified modeling language Modelica, a simulation model of the equipment is constructed, including the lubricating oil tank, lubricating oil pump, motor, overflow valve, filter, check valve, heat exchanger, heater, regulating valve, lubricating oil medium, pipeline model, and control module. The lubricating oil system model is then constructed based on the equipment simulation model.

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