Automatic monitoring and alarm system for diesel engine performance condition during durability bench testing

Abstract

This invention relates to an automatic monitoring and alarm system for the performance status of a diesel engine during durability bench testing, belonging to the field of diesel engine bench testing. The automatic monitoring and alarm system of this invention includes: a bench data acquisition system 2, an online statistical system for the entire durability test cycle 4, and a performance characteristic quantitative parameter acquisition system 8. This invention can improve the fault analysis capability at the diesel engine test site and greatly enhance the monitoring and early warning capability for gradual faults in diesel engines; it can enhance the bench system's ability to monitor abnormal diesel engine parameters and improve the bench system's automatic fault handling capability. From a safety production perspective, it increases the automatic protection measures for diesel engine and laboratory anomalies at the test site, reducing the expansion of losses to the diesel engine and laboratory caused by human factors; and it can provide test data support for diesel engine design optimization work after a fault occurs.

Description

Technical Field

[0001] This invention belongs to the field of diesel engine bench testing, specifically relating to an automatic monitoring and alarm system for the performance status of a diesel engine in durability bench testing. Background Technology

[0002] Durability testing is a necessary step in the diesel engine development process, verifying any durability issues with the entire engine and its components. Currently, high-pressure common rail turbocharged intercooled four-stroke diesel engines are widely used in various armored vehicles due to their excellent performance indicators, but there is still considerable room for improvement in their durability.

[0003] Dr. Zhao Leigang's dissertation at Wuhan University of Technology, titled "Research on Real-time Monitoring and Early Warning Methods for Engine Bench Testing," analyzes the types and causes of mechanical faults during engine testing. It proposes using vibration signals sensitive to faults to monitor the working state of the engine's main moving parts, identifying torque as an auxiliary monitoring parameter during the testing process. This method primarily monitors faults between the piston and cylinder liner, between the main bearing and main journal, and between the crankpin and connecting rod big-end bearing. However, it requires a high level of operator skill. Therefore, this method has limitations in the types of early warnings it can provide and is difficult to implement on-site.

[0004] Kong Xiangxin's invention patent, "A Real-Time Vibration Monitoring and Early Warning System for Diesel Engine Bench Tests," patent number CN201911330347, issued by the China North Engine Research Institute, addresses the shortcomings of current vibration monitoring technologies for long-cycle diesel engine bench tests (thousands of hours). These technologies suffer from problems such as system complexity, poor real-time performance and continuity, unreasonable alarm prediction and triggering, untimely alarm extrapolation, and a lack of interlocking mechanisms, resulting in low early fault identification rates and delayed detection of potential problems. To overcome these deficiencies, this invention provides a real-time vibration monitoring and early warning system for diesel engine bench tests. A deeper understanding of this patent reveals that while it can detect engine operating conditions and vibration, the early warning method is not detailed. For example, it does not elaborate on how to correlate abnormal engine vibration signals with abnormal engine components to determine the malfunction of a specific engine part. The core reason for addressing the problems of unreasonable alarm prediction and triggering, untimely alarm extrapolation, and lack of interlocking mechanisms is the system's poor early warning capability.

[0005] The master's thesis by Xu Xiaojin of Hefei University of Technology, titled "Research and Development of a Computerized Measurement and Control System for Engine Bench Testing," includes section 5.6.6 which details the setting of alarm parameters before the test. The thesis covers alarm detection and processing during the test, as well as the display of alarm records. The alarm method involves first selecting alarm parameters, then setting upper and lower limits, and finally, triggering the alarm processing section when an alarm is activated. Alarm types include display prompts, buzzers, and reducing idle speed. However, this method lacks further refinement and improvement, resulting in a rather crude alarm approach. It fails to reflect changes in alarm parameter limits with engine operating conditions and cannot detect trends in parameter changes during durability testing.

[0006] A high-pressure common rail turbocharged intercooled four-stroke diesel engine consists of a crankshaft and connecting rod mechanism, valve train, transmission mechanism, fuel supply system, lubrication system, cooling system, intake and exhaust system, and starting system. Dr. Zhao Leigang's dissertation at Wuhan University of Technology, "Research on Real-time Monitoring and Early Warning Methods for Engine Bench Tests," proposes an early warning method for crankshaft and connecting rod mechanism failures, but does not address other systems of the diesel engine. Kong Xiangxin's invention patent, "A Real-time Vibration Monitoring and Early Warning System for Diesel Engine Bench Tests," from the China North Engine Research Institute, can acquire engine operating conditions, detect vibrations, and provide early warnings, but it does not specify the relationship between the detection method (vibration signal) and the detection result (early warning), meaning the early warning method is unclear. Xu Xiaojin's master's thesis at Hefei University of Technology, "Research and Development of a Computerized Measurement and Control System for Engine Bench Tests," presents a rather crude early warning method that cannot accurately reflect changes in alarm parameters based on engine operating conditions, nor can it detect decreasing or increasing trends in durability test alarm parameters.

[0007] The types of faults encountered during the testing of the high-pressure common rail turbocharged intercooled four-stroke diesel engine included faults in the diesel engine's fuel supply system, cooling system, crankshaft and connecting rod mechanism, lubrication system, and intake and exhaust systems; details are as follows:

[0008] 1) Faults in the diesel engine fuel supply system include abnormal rail pressure control, abnormal injectors, and abnormal high-pressure fuel pump.

[0009] 2) Diesel engine cooling system malfunctions include abnormal water pump operation and abnormal coolant leakage;

[0010] 3) Faults in the crankshaft and connecting rod mechanism of diesel engines include piston and cylinder liner failures, and main bearing and main journal failures.

[0011] 4) Lubrication system malfunctions include slow and low lubricating oil pressure. Possible causes include abnormal lubricating oil pump or abnormal oil leakage from the lubricating oil passage. This type of malfunction is difficult to diagnose in engines.

[0012] 5) Diesel engine intake and exhaust faults: Abnormal exhaust temperature in one cylinder of a multi-cylinder diesel engine, abnormal turbocharger speed;

[0013] In summary, current durability test bench systems have limited alarm methods and functions, making it difficult to respond promptly to unexpected situations at the test site. This hinders on-site personnel from quickly detecting and handling sudden diesel engine failures. Furthermore, they cannot visually monitor the cumulative increase or decrease trends of diesel engine or component performance parameters during durability testing, hindering on-site personnel from detecting, predicting, and analyzing gradual diesel engine failures. Therefore, this invention proposes an automatic monitoring and alarm method for diesel engine performance status during durability bench testing. This invention enriches the alarm methods described in Xu Xiaojin's master's thesis, "Research and Development of Computerized Measurement and Control System for Engine Bench Testing," at Hefei University of Technology. Additionally, it innovatively proposes an online data statistics method for the entire durability test cycle to monitor the cumulative change trends of diesel engine performance parameters throughout the entire test cycle. Summary of the Invention

[0014] (a) Technical problems to be solved

[0015] The technical problem this invention aims to solve is how to provide an automatic monitoring and alarm system for the performance status of diesel engines in durability bench testing. This system addresses the shortcomings of current durability test bench systems, which have limited alarm methods and functions, making it difficult to respond promptly to unexpected situations at the test site. This hinders the rapid detection and timely handling of sudden diesel engine failures by test site personnel. Furthermore, the system cannot intuitively monitor the cumulative increase or decrease trend of performance parameters of diesel engines or components during durability testing, which is detrimental to the detection, prediction, and analysis of gradual diesel engine failures by test site personnel.

[0016] (II) Technical Solution

[0017] In order to solve the above technical problems, the present invention proposes an automatic monitoring and alarm system for diesel engine performance status in durability bench testing. The automatic monitoring and alarm system includes: bench data acquisition system (2), online statistical system for the entire durability test cycle (4), and performance characteristic quantitative parameter acquisition system (8).

[0018] The bench data acquisition system (2) is used to measure the diesel engine under test (1). It is a measuring device that directly measures the fluid temperature, pressure, flow rate, and diesel engine speed and torque. Each channel of the bench data acquisition system (2) is defined as a certain fluid measurement channel of the diesel engine according to its physical characteristics. The collection of all defined channels forms a measurement channel list. The measurement data is displayed in real time in the form of a list with a display frequency of 2Hz. The display content includes the physical location of the channel, the channel name, the value and the unit. At the same time, the system has a CAN communication interface and transmits the measurement data to the online statistical system (4) of the entire durability test cycle, the performance characteristic quantification parameter acquisition system (8) and the diesel engine multi-condition over-limit classification alarm system (13) at a communication rate of 2Hz. In addition, the system includes a first data storage module (3) with data storage function.

[0019] The online statistical system for the entire durability test cycle (4) includes: a data interaction module (5), an online statistical module (6), and a second data storage module (7). In addition, the system has a CAN communication interface to receive test data from the bench data acquisition system (2).

[0020] The data interaction module (5) is used to communicate with the bench data acquisition system (2) via CAN communication. The communication rate is 2Hz. This module acquires the measurement values ​​of the bench data acquisition system (2).

[0021] The online statistics module (6) displays the real-time curve of a single channel in real time using a single waveform graph, or displays the curves of multiple channels in real time using a single waveform graph. The real-time display curve is drawn from 1024 sampling points. If the sampling frequency is 2Hz, the real-time display curve can realize the monitoring of the change trend of a single channel for 512s. On the other hand, the cumulative change trend curve of a single channel is displayed in real time using a single waveform graph, or the cumulative change trend curve of multiple channels is displayed in a single waveform graph. During the durability test, the average value of each channel for 5 minutes is calculated according to the engine operating conditions. After a long time, the cumulative change trend curve is formed by multiple average values. The average values ​​are connected in sequence according to the time order to draw a curve. By observing the waveform graph, the cumulative change trend of a certain operating condition during the diesel engine durability test can be displayed intuitively.

[0022] The second data storage module (7) stores test data communicated between the bench data acquisition system (2) and the online statistical system (4) for the entire durability test cycle, as well as the average test data calculated by the online statistical system (4) for the entire durability test cycle. The two types of storage contents form multiple storage files.

[0023] The performance characteristic quantification parameter acquisition system (8) is used to obtain secondary calculation values ​​based on existing measurement data and numerical calculations. These calculation values ​​are parameters that can characterize the performance of diesel engines or components. These parameters are quantities that cannot be directly measured.

[0024] The diesel engine multi-condition over-limit classification alarm system (13) is equipped with: alarm parameter summary table (9), extreme parameter alarm list (10), important parameter alarm list (11), normal parameter alarm list (12), normal value upper limit array (14), engine condition array (15), normal value lower limit array (16), extreme parameter alarm processing strategy (17), important parameter alarm processing strategy (18), normal parameter alarm processing strategy (19) and third data storage module (20). The classification alarm system (13) is used to monitor extreme parameters, important parameters and normal parameters. According to the diesel engine operating conditions, when a parameter exceeds the set upper or lower limit, the corresponding alarm strategy is triggered.

[0025] Alarm Parameter Summary Table (9) consists of a direct measurement channel, a secondary calculation channel and a cumulative change trend of the channel that can characterize the performance and operating status of the diesel engine or component. The direct measurement channel is from the bench data acquisition system (2), the secondary calculation channel is from the performance characteristic quantification parameter acquisition system (8), and the cumulative change trend of the channel is from the online statistical system for the entire durability test cycle (4).

[0026] Extreme parameter alarm list (10), the extreme parameters are selected from the alarm parameter summary table (9), and the extreme parameter alarm table (10) is composed of multiple extreme parameters. The selection basis is that the abnormal parameter will seriously damage the diesel, cause a major hidden danger to the safety of the laboratory, cause serious damage to the test equipment, and have a certain degree of impact on the safety of the test personnel.

[0027] Important parameter alarm list (11) is selected from the alarm parameter summary table (9). The important parameter alarm list (11) is composed of multiple important parameters. The selection basis is that the abnormality of the parameter will have a significant impact on the normal conduct of the diesel engine bench test.

[0028] The list of routine parameter alarms (12) is selected from the alarm parameter summary table (9). The list of routine parameter alarms (12) consists of multiple routine parameters. The selection is based on the fact that the abnormality of the parameter has a certain impact on the normal conduct of the diesel engine bench test, but there is no risk of damage to the diesel engine, personnel, laboratory and equipment.

[0029] The normal value upper limit array (14) is used to store the upper limit value of each alarm parameter channel for each diesel engine test condition;

[0030] Engine operating condition array (15) is used to store each diesel engine test operating condition;

[0031] The normal value lower limit array (16) is used to store the lower limit value of each alarm parameter channel for each diesel engine test condition.

[0032] The extreme parameter alarm handling strategy (17) is triggered when the extreme parameter alarm occurs. The alarm strategy is to reduce the diesel engine idle speed and the dynamometer enters idle mode.

[0033] The alarm handling strategy for important parameters (18) is triggered when an important parameter alarm occurs. The alarm strategy is to make a buzzer sound and turn the alarm parameter font white to serve as a reminder. It does not affect the dynamometer or the diesel engine.

[0034] The handling strategy for routine parameter alarms (19) is triggered when a routine parameter alarm occurs. The alarm strategy is that the buzzer does not sound, only the alarm parameter font turns white to serve as a reminder, and there is no operation on the dynamometer and diesel engine.

[0035] The third data storage module (20) is used to store the data of the classification alarm system (13);

[0036] The first data storage module (3), the second data storage module (7), and the third data storage module (20) are stored in parallel.

[0037] (III) Beneficial Effects

[0038] This invention proposes an automatic monitoring and alarm system for the performance status of a diesel engine during durability bench testing. It also provides an automatic monitoring and alarm method for the performance status of a diesel engine during durability bench testing. This method combines online statistical methods throughout the entire durability testing cycle, fault classification and alarm methods, and data storage methods. The key points are the functional principles and implementation processes of each system.

[0039] Technical effects of the present invention:

[0040] 1. The online statistical method for the entire durability test cycle can improve the ability to analyze faults at the diesel engine test site and greatly enhance the monitoring and early warning capabilities for gradual faults in diesel engines.

[0041] 2. The fault classification alarm method can enhance the test bench system's ability to monitor abnormal diesel engine parameters and improve the test bench system's ability to automatically handle faults. From the perspective of safe production, it increases the automatic protection measures for abnormal diesel engines and test chambers at the test site, and reduces the expansion of diesel engine and test chamber losses caused by human factors.

[0042] 3. The fault classification alarm method and the online statistical method for the entire durability test cycle can provide test data support for diesel engine design optimization after a fault occurs. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of the automatic monitoring and alarm system for the performance status of diesel engine durability bench tests according to the present invention.

[0044] Figure 2 This is a data storage scheme for a parallel bus.

[0045] Figure 3 This is a diagram illustrating the effectiveness of the online statistical system for the entire durability testing cycle.

[0046] Figure 4 This is a diagram of the online statistical system for the entire durability test cycle. Detailed Implementation

[0047] To make the objectives, contents, and advantages of the present invention clearer, the specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples.

[0048] This invention addresses the requirements for diesel engine durability testing in GB-T 12679-1990 "Automobile Durability Driving Test Methods" 6.10 and GJB 59.62-1996 "Armored Vehicle Test Procedures Durability Test" 5.5, and considers the alarm requirements for high-pressure common rail diesel engines in bench tests. By analyzing the working principle, process, and operating conditions of diesel engines, this invention integrates multiple disciplines such as internal combustion engine science, testing technology, mathematical statistics, and computer science to innovatively propose an automatic monitoring and alarm method for diesel engine performance status in durability bench tests. This invention is of great significance for diesel engine performance monitoring, early fault prediction, and fault analysis in durability test benches.

[0049] According to the requirements for durability assessment tests in GB-T 12679-1990 "Automobile Durability Driving Test Method" 6.10 and GJB 59.62-1996 "Armor Vehicle Test Procedure Durability Test" 5.5, the performance status monitoring of a high-pressure common rail turbocharged intercooled four-stroke diesel engine was carried out on a diesel engine durability test bench. It was found that the current diesel engine durability test bench data system (2) mainly has the following shortcomings:

[0050] 1. It only has the function of real-time acquisition and display of test data, but it cannot intuitively monitor the changing trend of performance parameters of diesel engines or components in durability tests. It mainly relies on manual statistical methods of test data to obtain the cumulative increase or decrease trend of performance parameters of the whole machine and subsystems. This is not conducive to the discovery, prediction and analysis of gradual failure of diesel engines by on-site personnel. Moreover, manual statistical methods are inefficient and have a high error rate.

[0051] 2. Existing alarm methods are limited in function, only able to achieve single-limit alarms under all operating conditions. They cannot automatically adjust the upper and lower limits of the alarm according to the diesel engine's operating conditions to achieve fault classification alarms. If a fault occurs in the diesel engine or subsystem, it is difficult to respond to emergencies at the test site in a timely manner, which is not conducive to the rapid detection and timely handling of sudden diesel engine faults by test site personnel, and cannot stop losses in time.

[0052] This invention innovatively proposes a method for intuitively monitoring the cumulative increase or decrease trend of performance parameters in diesel engine or component durability tests. It relies on an industrial computer to automatically statistically analyze the performance status of the diesel engine. In terms of alarms in diesel engine bench tests, it continuously enriches the alarm methods described in Xu Xiaojin's master's thesis "Research and Development of Computer Measurement and Control System for Engine Bench Tests" at Hefei University of Technology. Combining the diesel engine's operating conditions, it relies on an industrial computer to automatically monitor three types of alarm parameters. If an alarm is triggered, it is automatically classified and processed.

[0053] This invention provides an automatic monitoring and alarm system for the performance status of a diesel engine during durability bench testing, comprising: an online statistical system for the entire durability test cycle and a multi-condition over-limit classification alarm system for the diesel engine. The two systems and methods correspond to different data storage strategies, detailed as follows: Figure 1 As shown.

[0054] The diesel engine performance status automatic monitoring and alarm system for durability bench testing includes: bench data acquisition system (2), online statistical system for the entire durability test cycle (4), and performance characteristic quantitative parameter acquisition system (8);

[0055] The diesel engine under test (1) can be a high-pressure common rail turbocharged intercooled four-stroke diesel engine, an inline pump turbocharged intercooled four-stroke diesel engine, or a unit pump turbocharged intercooled four-stroke diesel engine.

[0056] The bench data acquisition system (2) is used to measure the diesel engine under test (1). It is a measuring device that directly measures the fluid temperature, pressure, flow rate, and diesel engine speed and torque. For example, it measures the temperature, pressure, and flow rate of fuel, lubricating oil, coolant, intake air and exhaust air. Each channel of the bench data acquisition system (2) is defined as a certain fluid measurement channel of the diesel engine according to its physical characteristics. For example, a certain T-type thermocouple channel is defined as the coolant inlet temperature, a certain K-type thermocouple channel is defined as the diesel engine left exhaust temperature, and a certain pressure transmitter channel is defined as the coolant inlet pressure. The collection of all defined channels forms a measurement channel list. The measurement data is displayed in real time in the form of a list with a display frequency of 2Hz. The display content includes the physical location of the channel, the channel name, the value and the unit. At the same time, the system has a CAN communication interface and can transmit the measurement data to the online statistical system (4) of the entire durability test cycle, the performance characteristic quantification parameter acquisition system (8) and the diesel engine multi-condition over-limit classification alarm system (13) at a communication rate of 2Hz. In addition, the system includes a first data storage module (3) with data storage function.

[0057] The first data storage module (3) is used to store the full-channel data of the bench data acquisition system (2). The storage method is sequential storage. The storage marker is: the file name starts with 1-. The storage condition is: storage starts when the test begins and stops when the test ends. The storage frequency is 2Hz. The storage file type is: excel. The storage location is: the hard disk of the hardware platform on which the bench data acquisition system (2) runs.

[0058] The online statistical system for the entire durability test cycle (4) includes: a data interaction module (5), an online statistical module (6), and a second data storage module (7). In addition, the system has a CAN communication interface to receive test data from the bench data acquisition system (2).

[0059] The data interaction module (5) is used for the online statistical system (4) of the entire durability test cycle to communicate with the bench data acquisition system (2) via CAN communication at a rate of 2Hz. This module acquires the measurement values ​​of the bench data acquisition system (2). The data interaction module (5) is responsible for setting the CAN communication parameters of the online statistical system (4) of the entire durability test cycle, including CAN card selection, CAN card enable / disable, and baud rate setting. On the other hand, it reads the test data of the bench data acquisition system (2) and parses the read messages into decimal numerical form for easy display and storage.

[0060] The online statistics module (6) displays the real-time curve of a single channel in real time using a single waveform graph, or displays the curves of multiple channels in real time using a single waveform graph. The real-time display curve is drawn from 1024 sampling points. If the sampling frequency is 2Hz, the real-time display curve can realize the monitoring of the change trend of a single channel for 512s. On the other hand, it displays the cumulative change trend curve of a single channel in real time using a single waveform graph, or displays the cumulative change trend curve of multiple channels in a single waveform graph. During the durability test, the average value of each channel for 5 minutes is calculated according to the engine operating conditions. After a long time, the cumulative change trend curve will be formed by multiple average values. The average values ​​are connected in sequence according to the time order to draw the curve. By observing the waveform graph, the cumulative change trend of a certain operating condition during the diesel engine durability test can be displayed intuitively. For example, if the diesel engine durability test lasts for 500 hours and there is one operating condition, then one channel will generate 6,000 average values. The curve drawn from these 6,000 average values ​​can show the trend of diesel engine durability throughout the entire test cycle. If there are multiple operating conditions for diesel engine durability testing, then the above method can be used to classify and statistically analyze them according to the diesel engine operating conditions.

[0061] The second data storage module (7) stores test data communicated between the bench data acquisition system (2) and the online statistical system (4) for the entire durability test cycle, as well as the average test data calculated by the online statistical system (4) for the entire durability test cycle. The two types of storage content form multiple storage files. There are a total of 4 operating conditions in the engine durability test, so there are a total of 5 storage files. The first storage file is the data stored in real time for 5 minutes. The second storage file is the average value calculated after every 5 minutes of operation in engine durability test condition 1. The third storage file is the average value calculated after every 5 minutes of operation in engine durability test condition 2. The fourth storage file is the average value calculated after every 5 minutes of operation in engine durability test condition 3. The fifth storage file is the average value calculated after every 5 minutes of operation in engine durability test condition 4. When the engine is undergoing a normal durability test, firstly, a 5-minute storage space is created for all channels, with the file type being Excel, the storage frequency being 2Hz, and the location being the hard drive of the hardware platform on which the online statistical system (4) for the entire durability test cycle is running; secondly, after the diesel engine runs continuously for 5 minutes under a certain operating condition, the average value of 600 sampling points within each channel within 5 minutes is processed; finally, the average value is classified and stored in the storage file corresponding to the operating condition according to the engine operating condition, and the storage file is located on the hard drive of the hardware platform on which the online statistical system (4) for the entire durability test cycle is running. When the engine is undergoing an abnormal durability test, that is, when the operating condition runs for less than 5 minutes, the average value is calculated according to the actual duration and stored in the corresponding operating condition storage file.

[0062] The performance characteristic quantification parameter acquisition system (8) is used to obtain secondary calculation values ​​after numerical calculation based on existing measurement data. These calculation values ​​are parameters that can characterize the performance of diesel engines or components. These parameters are quantities that cannot be directly measured. For example, power is obtained by numerical calculation of speed and torque, and specific fuel consumption is obtained by numerical calculation of speed, torque, and fuel consumption.

[0063] The diesel engine multi-condition over-limit classification alarm system (13) is equipped with: alarm parameter summary table (9), extreme parameter alarm list (10), important parameter alarm list (11), normal parameter alarm list (12), normal value upper limit array (14), engine operating condition array (15), normal value lower limit array (16), extreme parameter alarm processing strategy (17), important parameter alarm processing strategy (18), normal parameter alarm processing strategy (19) and third data storage module (20). The classification alarm system (13) is used to monitor extreme parameters, important parameters and normal parameters. According to the diesel engine operating conditions, when a parameter exceeds the set upper or lower limit, the corresponding alarm strategy is triggered.

[0064] The alarm parameter summary table (9) consists of direct measurement channels, secondary calculation channels, and cumulative change trends of the channels that characterize the performance and operating status of the diesel engine or components. The direct measurement channels are derived from the bench data acquisition system (2), the secondary calculation channels are derived from the performance characteristic quantification parameter acquisition system (8), and the cumulative change trends of the channels are derived from the online statistical system for the entire durability test cycle (4). For example, the performance of the diesel engine is characterized by three measured values: diesel engine speed, diesel engine torque, and diesel engine fuel consumption; the diesel engine cooling system is characterized by six parameters: diesel engine inlet water temperature, inlet water pressure, water pump outlet temperature, water pump outlet pressure, diesel return water temperature, and diesel engine return water pressure.

[0065] The extreme parameter alarm list (10) is composed of multiple extreme parameters selected from the alarm parameter summary table (9). The selection criteria are that the abnormality of the parameter causes serious damage to diesel fuel, poses a significant safety hazard to the laboratory, causes serious damage to the test equipment, and has a certain impact on the safety of the test personnel. The parameters involved in the extreme parameter alarm list (10) include diesel engine speed, diesel engine torque, diesel engine fuel consumption, turbocharger speed, etc.

[0066] The list of important parameters (11) is selected from the alarm parameter summary table (9). The list of important parameters (11) consists of multiple important parameters. The selection criteria is that abnormal parameters will have a significant impact on the normal conduct of diesel engine bench tests. The parameters involved in the list of important parameters (11) include main oil passage pressure, water pump after pressure, low-pressure fuel pump after fuel pressure, engine oil inlet temperature, engine water inlet temperature, fuel inlet temperature, exhaust gas pressure, and turbine exhaust temperature.

[0067] The routine parameter alarm list (12) is composed of multiple routine parameters selected from the alarm parameter summary table (9). The selection is based on the fact that the abnormality of the parameter has a certain impact on the normal conduct of the diesel engine bench test, but there is no risk of damage to the diesel engine, personnel, laboratory and equipment. The parameters involved in the routine parameter alarm list (12) include engine intake air temperature, engine intake air pressure, etc.

[0068] The normal value upper limit array (14) is used to store the upper limit value of each alarm parameter channel for each diesel engine test condition, as shown in Table 2.

[0069] An engine operating condition array (15) is used to store the test operating conditions of each diesel engine, as shown in Table 2.

[0070] The normal value lower limit array (16) is used to store the lower limit value of each alarm parameter channel for each diesel engine test condition, as shown in Table 2.

[0071] The extreme parameter alarm handling strategy (17) is triggered when the extreme parameter alarm occurs. The alarm strategy is to reduce the diesel engine idle speed and the dynamometer enters idle mode.

[0072] The alarm handling strategy for important parameters (18) is triggered when an important parameter alarm occurs. The alarm strategy is to make a buzzer sound and turn the alarm parameter font white to serve as a reminder. It does not affect the dynamometer or the diesel engine.

[0073] The handling strategy for routine parameter alarms (19) is triggered when a routine parameter alarm occurs. The alarm strategy is that the buzzer does not sound, only the alarm parameter font turns white to serve as a reminder, and there is no operation on the dynamometer and diesel engine.

[0074] The third data storage module (20) is used to store the data of the classification alarm system (13). The storage method is a push-and-pop method. The buffer size of stack 1 is designed to be 21MB to meet the data storage capacity of 10min, 100Hz frequency, and 100 channels. The storage marker is that the file name starts with 2-. The storage channels are all channels of the benchtop data acquisition system. The storage conditions are as follows: when the data acquisition system starts working, stack 1 is created. When a certain channel in the alarm parameter table (9) triggers the alarm upper or lower limit, the data in the time period of 5 minutes before and 5 minutes after the alarm is read from stack 1. Test data for a specific time period is not read; instead, a file named "2-Channel Alarm-Time" is created and stored. If multiple channels trigger the upper or lower alarm limit at the same time, the above method is used to create multiple "2-Channel Alarm-Time" files and store them. If the time interval between two alarms is less than 5 minutes, the above method is still used to create and store "2-Channel Alarm-Time" files. No other operations are performed on the data in the stack. Storage frequency: 2Hz; File type: Excel; Storage location: Hard disk of the hardware platform on which the benchtop data acquisition system runs.

[0075] Example 1:

[0076] Data storage solutions

[0077] The data storage scheme includes the first data storage module (3) of the bench data acquisition system (2), the second data storage module (7) of the online statistical system for the entire durability test cycle (4), and the third data storage module (20) of the classification alarm system (13). The second data storage module (7) stores the real-time test data received from communication and the cumulative average value. The three data storage modules adopt a parallel storage method. For details, see [link to scheme]. Figure 2 Each storage scheme is described in detail below:

[0078] The first data storage module (3) is as follows Figure 2 As shown. Storage method: sequential storage; storage tag: first storage file; storage channel: all channels of the bench data acquisition system; storage conditions: storage starts at the beginning of the test and stops at the end of the test; storage frequency: 2Hz; storage file type: excel; storage location: hard disk of the hardware platform on which the bench data acquisition system runs.

[0079] The second data storage module (7) is as follows Figure 2As shown. There are two types of stored content. The first type of stored content is the real-time test data communicated between the bench data acquisition system (2) and the online statistical system (4) for the entire durability test cycle. The second type of stored content is the average test data calculated by the online statistical system (4) for the entire durability test cycle. The two types of stored content form multiple storage files.

[0080] The storage method for the first type of storage content is: stack push and pop storage. The design of the stack 2 cache size is 10.5MB, which meets the data storage capacity of 5min, 100hz frequency, and 100 channels. When the storage file cache is less than 10.5MB, the data is stored into the file in sequence. When the storage file cache reaches 10.5MB, the data stored later will push out the data stored earlier. Storage mark: 3rd storage file; Storage channel: The channel contained in the real-time test data communicated between the bench data acquisition system (2) and the online statistical system for the entire durability test cycle (4); Storage conditions: If the communication between the bench data acquisition system (2) and the online statistical system for the entire durability test cycle (4) is established, storage will start; otherwise, storage will stop; Storage frequency: 2Hz; Storage file type: excel; Storage location: The hard disk of the hardware platform on which the online statistical system for the entire durability test cycle (4) runs.

[0081] The second type of storage method: Based on engine operating conditions, when a certain operating condition has run for 5 minutes, the average value of the data in stack 2 is calculated. If the engine needs to switch operating conditions, and the current operating condition does not meet the 5-minute duration, the average value is still calculated based on the actual duration. Each average value is stored sequentially according to the engine operating time. Storage marking: Based on the engine durability test conditions, taking Table E.1 of Appendix E of GJB5464.1 as an example, the diesel engine durability test consists of 9 sub-cycles. Five of these sub-cycles have shorter operating times and are not included in the statistics. The remaining four operating conditions have longer operating times. The four operating conditions are: Operating Condition 1: The speed is the punctuated speed. Operating condition 1 is 100% of the maximum torque, with the torque value determined by the external characteristics, and a running time of 60 minutes; Operating condition 2 is 85% to 90% of the maximum torque, with the torque value determined by the external characteristics, and a running time of 420 minutes; Operating condition 3 is 80% of the maximum torque, with the torque value determined by the external characteristics, and a running time of 100 minutes; Operating condition 4 is the speed corresponding to the maximum torque, with the torque value being the maximum torque, and a running time of 20 minutes. The duration of each operating condition is an integer multiple of 5 minutes. Four storage files are created respectively: 4-Operating Condition 1 storage file, 4-Operating Condition 2 storage file, 4-Operating Condition 3 storage file, and 4-Operating Condition 4 storage file. The data stored in the 4-condition 1 storage file is the average value calculated after every 5 minutes of operation of the engine durability test condition 1. The data stored in the 4-condition 2 storage file is the average value calculated after every 5 minutes of operation of the engine durability test condition 2. The data stored in the 4-condition 3 storage file is the average value calculated after every 5 minutes of operation of the engine durability test condition 3. The data stored in the 4-condition 4 storage file is the average value calculated after every 5 minutes of operation of the engine durability test condition 4. Storage channel: The channel containing the real-time test data communicated between the bench data acquisition system (2) and the online statistical system (4) for the entire durability test cycle. Storage conditions: When a certain condition is continuously operated for 5 minutes or when switching conditions, the operation time is less than 5 minutes. Storage frequency: Once every 5 minutes or when switching conditions. Storage file type: excel. Storage location: The hard disk of the hardware platform on which the online statistical system (4) for the entire durability test cycle runs.

[0082] The third data storage module (20) is as follows Figure 2As shown. Storage method: Stack push and pop method, the cache size of stack 1 is designed to be 21MB, which meets the data storage capacity of 10min, 100hz frequency, and 100 channels; Storage mark: the second storage file; Storage channel: all channels of the bench data acquisition system; Storage conditions: when the data acquisition system starts working, stack 1 is created. When a certain channel in the alarm parameter table (9) triggers the alarm upper or lower limit, the data in the time period of 5min before and 5min after the alarm is read from stack 1. The test data in other time periods is not read, forming a "2-a certain channel alarm-time" file and storing it; if multiple channels trigger the alarm upper or lower limit at the same time, the above method is used to form multiple "2-a certain channel alarm-time" files and store them; if the time interval between two alarms is less than 5min, the above method is still used to form "2-a certain channel alarm-time" files and store them; no other operations are performed on the data in the stack; Storage frequency: 2Hz; Storage file type: excel; Storage location: the hard disk of the hardware platform on which the bench data acquisition system runs.

[0083] Online statistical method for the entire durability test cycle:

[0084] The online statistical system (4) for the entire durability test cycle and the bench data acquisition system (2) interact in real time via CAN bus to draw real-time monitoring charts of key parameters. Then, the online statistical trend chart is obtained by processing the data using the equal-time online averaging method. Through the intuitive display of the real-time monitoring chart and the online statistical trend chart, on-site test personnel can conduct online monitoring and early fault prediction of the entire test cycle of the whole machine and its components, which greatly improves the monitoring and early warning capabilities of the gradual failure of the diesel engine.

[0085] The online statistical system for the entire durability test cycle (4) mainly implements the following steps in its online statistical method for the entire durability test cycle:

[0086] S11, Durability full test cycle online statistical system (4) Communication settings.

[0087] The data interaction module (5) is used to implement and complete the setting of parameters such as CAN card selection, CAN card enable and disable, and baud rate setting.

[0088] S12. Establish a communication connection between the online statistical system (4) for the entire durability test cycle and the bench data acquisition system (2).

[0089] The communication connection is established between the two systems using CANopen communication mode, with a communication frequency of 2Hz.

[0090] S13. Analyze communication messages.

[0091] The message is parsed through the data interaction module (5) and parsed into decimal numerical form;

[0092] S14. Establish a data storage mechanism.

[0093] The second data storage module (7) completes the storage. There are two types of storage content. The first type of storage content is the real-time test data communicated between the bench data acquisition system (2) and the online statistical system (4) for the entire durability test cycle. The second type of storage content is the average test data calculated by the online statistical system (4) for the entire durability test cycle. The two types of storage content form multiple storage files.

[0094] The first type of storage method: stack push and pop storage. The design of stack 2 is 10.5MB of cache size, which meets the data storage capacity of 5min, 100Hz frequency and 100 channels. When the storage file cache is less than 10.5MB, the data is stored into the file in sequence. When the storage file cache reaches 10.5MB, the data stored later will push the data stored earlier out. Storage mark: 3rd storage file; Storage channel: The channel contained in the real-time test data communicated between the bench data acquisition system (2) and the online statistical system (4) for the entire durability test cycle; Storage conditions: If the communication between the bench data acquisition system (2) and the online statistical system (4) for the entire durability test cycle is established, storage will start. Otherwise, storage will stop; Storage frequency: 2Hz; Storage file type: excel; Storage location: Hard disk of the hardware platform on which the online statistical system (4) for the entire durability test cycle runs.

[0095] The second type of storage method: Based on engine operating conditions, when a certain operating condition has run for 5 minutes, the average value of the data in stack 2 is calculated. If the engine needs to switch operating conditions, and the current operating condition does not meet the 5-minute duration, the average value is still calculated based on the actual duration. Each average value is stored sequentially according to the engine operating time. Storage marking: Based on the engine durability test conditions, taking Table E.1 of Appendix E of GJB5464.1 as an example, the diesel engine durability test has a total of 9 sub-cycles. Five of these sub-cycles have shorter operating times and are not included in the statistics. The remaining four operating conditions have longer operating times. The four operating conditions are: Operating Condition 1, where the speed is the calibrated speed... Condition 1: 100% torque is executed according to external characteristics, running time 60 minutes; Condition 2: speed is 85%~90% of the marked speed, torque is executed according to external characteristics, running time 420 minutes; Condition 3: speed is 80% of the marked speed, torque is executed according to external characteristics, running time 100 minutes; Condition 4: speed is the speed corresponding to the maximum torque, torque is the maximum torque, running time 20 minutes, and the duration of each condition is an integer multiple of 5 minutes. Four storage files are created respectively: 4-condition 1 storage file, 4-condition 2 storage file, 4-condition 3 storage file, and 4-condition 4 storage file. The data stored in the 4-condition 1 storage file is the average value calculated after every 5 minutes of operation of the engine durability test condition 1. The data stored in the 4-condition 2 storage file is the average value calculated after every 5 minutes of operation of the engine durability test condition 2. The data stored in the 4-condition 3 storage file is the average value calculated after every 5 minutes of operation of the engine durability test condition 3. The data stored in the 4-condition 4 storage file is the average value calculated after every 5 minutes of operation of the engine durability test condition 4. Storage channel: The channel containing the real-time test data communicated between the bench data acquisition system (2) and the online statistical system (4) for the entire durability test cycle. Storage conditions: When a certain condition is continuously operated for 5 minutes or when switching conditions, the operation time is less than 5 minutes. Storage frequency: Once every 5 minutes or when switching conditions. Storage file type: excel. Storage location: The hard disk of the hardware platform on which the online statistical system (4) for the entire durability test cycle runs.

[0096] Examples are shown in Table 1. According to the requirements of Appendix E, Table E.1 of GJB5464.1, the storage method for the four operating conditions of the durability test is as described above: 12 lines are stored for each cycle of operating condition 1, 84 lines for each cycle of operating condition 2, 20 lines for each cycle of operating condition 3, and 4 lines for each cycle of operating condition 4. If the engine durability test duration is 500 hours (i.e., 50 cycles are required), then 600 lines are stored for operating condition 1, 4200 lines for each cycle of operating condition 2, 1000 lines for each cycle of operating condition 3, and 200 lines for each cycle of operating condition 4. If the engine experiences an abnormality during the durability test, i.e., the operating condition runs for less than 5 minutes, the average value calculated based on the actual duration is stored in the corresponding operating condition file.

[0097] Table 1 Examples of Alarm Methods

[0098]

[0099] S15. Real-time online monitoring is achieved.

[0100] The online statistics module (6) completes the following steps: First, it determines how many channel curves the real-time display waveform graph will display; second, it reads the data from the first type of storage file, i.e., stack 2. The reading condition is that after each line of the first type of storage file is stored, the data of that line is read; finally, it filters out the channels that need to be displayed and displays the values ​​on the waveform graph in a dotted manner.

[0101] S16. Achieve cumulative online monitoring.

[0102] The online statistics module (6) completes the following steps: First, it determines the engine durability test conditions; second, it determines how many channels of curves to display in the cumulative display waveform diagram; third, it reads the corresponding sequence number file storage according to the engine durability test conditions, and the reading condition is that after each line of the corresponding sequence number storage file is stored, the data of that line is read; finally, it filters out the channels that need to be displayed and displays the values ​​on the waveform diagram in a dotted manner.

[0103] Alarm methods:

[0104] Based on the operating conditions, working process, and key parameter change trends of the whole machine and subsystems, the alarm methods are divided into three types: extreme parameter abnormality alarm, important parameter abnormality alarm, and routine parameter abnormality alarm. The alarm parameters are mainly selected from the bench data acquisition system (2), the performance characteristic quantification parameter acquisition system (8), and the online statistical system for the entire durability test cycle (4). Combined with the engine operating conditions, the real-time values ​​of the alarm parameter summary table (9) are used to trigger an over-limit alarm.

[0105] Depend on Figure 1 It can be seen that the alarm parameter summary table (9) is provided by the online statistical system (4) for the entire durability test cycle, the bench data acquisition system (2), and the performance characteristic quantitative parameter acquisition system (8). The online statistical system (4) for the entire durability test cycle provides quantitative parameters of the performance status change trend of the diesel engine or subsystem, such as how much the main oil passage pressure increases under a certain operating condition of the diesel engine; the bench data acquisition system (2) provides direct measurement parameters; the performance characteristic quantitative parameter acquisition system (8) provides secondary calculation values ​​that can characterize the performance status of the diesel engine; for example, power, specific fuel consumption, inlet water temperature difference, inlet and outlet oil temperature difference, and left and right exhaust temperature difference.

[0106] The alarm parameters in the alarm parameter summary table (9) are divided into three categories: extreme alarm parameters, important alarm parameters, and regular alarm parameters.

[0107] Extreme parameters are selected from the alarm parameter summary table (9), and the extreme parameter alarm table (10) is composed of multiple extreme parameters. The selection criteria are that the abnormality of the parameter will cause serious damage to diesel fuel, pose a significant safety hazard to the laboratory, cause serious damage to the test equipment, and have a certain degree of impact on the safety of the test personnel. The parameters involved in the extreme parameter alarm list (10) include diesel engine speed, diesel engine torque, diesel engine fuel consumption, turbocharger speed, etc.

[0108] Important parameters are selected from the alarm parameter summary table (9), and an important parameter alarm table (11) is composed of multiple important parameters. The selection is based on the degree of influence of the parameter on the normal conduct of the diesel engine bench test. The parameters involved in the important parameter alarm list (11) include main oil passage pressure, water pump after pressure, low-pressure fuel pump after fuel pressure, engine oil inlet temperature, engine water inlet temperature, fuel inlet temperature, exhaust gas pressure, turbine exhaust temperature, etc.

[0109] The routine parameters are selected from the alarm parameter summary table (9), and the routine parameter alarm table (12) is composed of multiple routine parameters. The selection is based on the fact that the abnormality of the parameter has a certain impact on the normal conduct of the diesel engine bench test, but there is no risk of damage to the diesel engine, personnel, laboratory and equipment. The parameters involved in the routine parameter alarm list (12) include engine intake air temperature, engine intake air pressure, etc.

[0110] In the classified alarm system (13), the alarm methods are exemplified in Table 2.

[0111] S21. The normal value of the alarm parameter for each operating condition is obtained from the engine external characteristic test;

[0112] S22. Determine the engine test conditions, determine the upper and lower limits of the alarm parameters of the test conditions, and form an engine test condition array (15) with multiple conditions, form a normal value upper limit array (14) with the upper limits of multiple alarm parameters, and form a normal value lower limit array (16) with the lower limits of multiple alarm parameters.

[0113] S23. Determine whether the detection alarm parameters of the engine test condition exceed the set upper or lower limit;

[0114] S24. If the limit is exceeded, an alarm will be triggered; if the limit is not exceeded, no alarm will be triggered.

[0115] After an alarm is triggered, the alarm will be classified and handled accordingly:

[0116] First, determine the alarm for one or more alarm parameters. Second, determine the alarm parameter classification type. Finally, determine the alarm handling strategy based on the alarm parameter type. The alarm handling strategies are divided into three categories: handling strategy for normal parameter alarms (19), handling strategy for important parameter alarms (18), and handling strategy for normal parameter alarms (19). When an extreme alarm parameter is triggered, the handling strategy for normal parameter alarms (19) is triggered. When an important parameter is triggered, the handling strategy for important parameter alarms (18) is triggered. When a normal parameter is triggered, the handling strategy for normal parameter alarms (19) is triggered.

[0117] Extreme parameter alarm handling strategy (17): When an extreme parameter alarm occurs, this alarm strategy is triggered. The alarm strategy is to reduce the diesel engine idle speed and the dynamometer enters idle mode.

[0118] Important parameter alarm handling strategy (18): When an important parameter alarm occurs, this alarm strategy is triggered. The alarm strategy is to sound the buzzer and turn the alarm parameter font white to serve as a reminder. It does not affect the dynamometer or diesel engine.

[0119] The handling strategy for routine parameter alarms (19): When a routine parameter alarm occurs, this alarm strategy is triggered. The alarm strategy is that the buzzer does not sound, only the alarm parameter font turns white to serve as a reminder, and there is no operation on the dynamometer and diesel engine.

[0120] Alarm Records:

[0121] If an alarm is triggered by a channel in the alarm parameter master table (9) after detection and judgment by the classification alarm system (13), an alarm record is triggered. All three types of alarm parameters use the same alarm record. The alarm record is implemented and completed by data storage scheme 3 (20). Storage method: Stack push and pop method, the cache size of stack 1 is designed to be 21MB, which meets the data storage capacity of 10min, 100hz frequency and 100 channels; storage mark: second storage file; storage channel: all channels of the bench data acquisition system; storage conditions: when the data acquisition system starts working, stack 1 is created. When a certain channel in the alarm parameter table (9) triggers the alarm upper or lower limit, the data in the time period of 5min before and 5min after the alarm is read from stack 1. The test data in other time periods is not read, forming a "2-a certain channel alarm-time" file and storing it; if multiple channels trigger the alarm upper or lower limit at the same time, the above method is used to form multiple "2-a certain channel alarm-time" files and store them; if the time interval between two alarms is less than 5min, the above method is still used to form "2-a certain channel alarm-time" files and store them; no other operations are performed on the data in the stack; storage frequency: 2Hz; storage file type: excel; storage location: hard disk of the hardware platform on which the bench data acquisition system runs.

[0122] Other notes:

[0123] Table 2 Examples of Alarm Methods

[0124]

[0125] In the online statistical system covering the entire durability test cycle, diesel engine speed, torque, main oil passage pressure, and return oil temperature were selected as key parameters for monitoring. Figure 3 This is a demonstration image of the online statistical system for the entire durability testing cycle:

[0126] 1. Data Acquisition System Acquisition Channel List:

[0127] Appendix 1: List of Data Acquisition Channels for the Data Acquisition System

[0128]

[0129] 2. National standards for bench testing of vehicle durability, including diesel engine durability:

[0130] According to GB-T 12679-1990 "Test Methods for Durability of Automobiles", 6.10, a 25% reduction in vehicle power performance and a 30% increase in fuel consumption are both considered fatal faults.

[0131] 3. Requirements of the National Military Standard for Durability Bench Testing of Complete Vehicles, Including Diesel Engines:

[0132] According to GJB 59.62-1996 "Armored Vehicle Test Procedures - Durability Test" 5.5, where there are specific requirements for the durability indicators of armored vehicle samples, the evaluation should be conducted by comparing the test results with tactical indicators. When the durability reaching the specified service life is equal to or higher than the durability and confidence level requirements specified in the "Development Task Book", it is deemed acceptable.

[0133] 4. National military standards specify the procedures and methods for engine durability testing:

[0134] Appendix E.1.3.3 of GJB5464.1 "Armored Vehicle Diesel Engine Frame Test Part 1: Standard Reference Conditions, Calibration and Test Methods for Power, Fuel Consumption and Oil Consumption" states that the durability test is divided into several independent stages, with each stage lasting 50 hours and each working cycle lasting 10 hours. The diesel engine is tested according to the provisions of Table E.1 for each working cycle.

[0135] 5. A diagram of the online statistical system for the entire durability testing cycle is shown below. Figure 4 As shown.

[0136] This invention provides an automatic monitoring and alarm method for the performance status of a diesel engine during durability bench testing. The method combines an online statistical method for the entire durability test cycle, a fault classification alarm method, and a data storage method. The key points are the functional principles and implementation process of each system.

[0137] Technical effects of the present invention:

[0138] 1. The online statistical method for the entire durability test cycle can improve the ability to analyze faults at the diesel engine test site and greatly enhance the monitoring and early warning capabilities for gradual faults in diesel engines.

[0139] 2. The fault classification alarm method can enhance the test bench system's ability to monitor abnormal diesel engine parameters and improve the test bench system's ability to automatically handle faults. From the perspective of safe production, it increases the automatic protection measures for abnormal diesel engines and test chambers at the test site, and reduces the expansion of diesel engine and test chamber losses caused by human factors.

[0140] 3. The fault classification alarm method and the online statistical method for the entire durability test cycle can provide test data support for diesel engine design optimization after a fault occurs.

[0141] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. An automatic monitoring and alarm system for the performance status of a diesel engine during durability bench testing, characterized in that, The automatic monitoring and alarm system includes: a bench data acquisition system (2), an online statistical system for the entire durability test cycle (4), and a performance characteristic quantitative parameter acquisition system (8). The bench data acquisition system (2) is used to measure the diesel engine under test (1). It is a measuring device that directly measures the fluid temperature, pressure, flow rate, and diesel engine speed and torque. Each channel of the bench data acquisition system (2) is defined as a certain fluid measurement channel of the diesel engine according to its physical characteristics. The collection of all defined channels forms a measurement channel list. The measurement data is displayed in real time in the form of a list with a display frequency of 2Hz. The display content includes the physical location of the channel, the channel name, the value and the unit. At the same time, the system has a CAN communication interface and transmits the measurement data to the online statistical system (4) of the entire durability test cycle, the performance characteristic quantification parameter acquisition system (8) and the diesel engine multi-condition over-limit classification alarm system (13) at a communication rate of 2Hz. In addition, the system includes a first data storage module (3) with data storage function. The online statistical system for the entire durability test cycle (4) includes: a data interaction module (5), an online statistical module (6), and a second data storage module (7). In addition, the system has a CAN communication interface to receive test data from the bench data acquisition system (2). The data interaction module (5) is used to communicate with the bench data acquisition system (2) via CAN communication. The communication rate is 2Hz. This module acquires the measurement values ​​of the bench data acquisition system (2). The online statistics module (6) displays the real-time curve of a single channel in real time using a single waveform graph, or displays the curves of multiple channels in real time using a single waveform graph. The real-time display curve is drawn from 1024 sampling points. If the sampling frequency is 2Hz, the real-time display curve can realize the monitoring of the change trend of a single channel for 512s. On the other hand, the cumulative change trend curve of a single channel is displayed in real time using a single waveform graph, or the cumulative change trend curve of multiple channels is displayed in a single waveform graph. During the durability test, the average value of each channel for 5 minutes is calculated according to the engine operating conditions. After a long time, the cumulative change trend curve is formed by multiple average values. The average values ​​are connected in sequence according to the time order to draw the curve. By observing the waveform graph, the cumulative change trend of a certain operating condition during the diesel engine durability test can be displayed intuitively. The second data storage module (7) stores test data from communication between the bench data acquisition system (2) and the online statistical system (4) for the entire durability test cycle, as well as the average test data calculated by the online statistical system (4) for the entire durability test cycle. The two types of storage contents form multiple storage files. The performance characteristic quantification parameter acquisition system (8) is used to obtain secondary calculated values ​​based on existing measurement data and numerical calculations. These calculated values ​​are parameters that can characterize the performance of diesel engines or components; such parameters cannot be directly measured. The diesel engine multi-condition over-limit classification alarm system (13) is equipped with: alarm parameter summary table (9), extreme parameter alarm list (10), important parameter alarm list (11), normal parameter alarm list (12), normal value upper limit array (14), engine condition array (15), normal value lower limit array (16), extreme parameter alarm processing strategy (17), important parameter alarm processing strategy (18), normal parameter alarm processing strategy (19) and third data storage module (20). The classification alarm system (13) is used to monitor extreme parameters, important parameters and normal parameters. According to the diesel engine operating conditions, when a parameter exceeds the set upper or lower limit, the corresponding processing strategy is triggered. Alarm Parameter Summary Table (9) consists of a direct measurement channel, a secondary calculation channel and a cumulative change trend of the channel that can characterize the performance and operating status of the diesel engine or component. The direct measurement channel is from the bench data acquisition system (2), the secondary calculation channel is from the performance characteristic quantification parameter acquisition system (8), and the cumulative change trend of the channel is from the online statistical system for the entire durability test cycle (4). Extreme parameter alarm list (10), the extreme parameters are selected from the alarm parameter table (9), and the extreme parameter alarm list (10) is composed of multiple extreme parameters. The selection basis is that the abnormal parameter will seriously damage the diesel, cause a major hidden danger to the safety of the laboratory, cause serious damage to the test equipment, and have a certain degree of impact on the safety of the test personnel. Important parameter alarm list (11) is selected from the alarm parameter summary table (9). The important parameter alarm list (11) is composed of multiple important parameters. The selection basis is that the abnormality of the parameter will have a significant impact on the normal conduct of the diesel engine bench test. The list of routine parameter alarms (12) is selected from the alarm parameter summary table (9). The list of routine parameter alarms (12) consists of multiple routine parameters. The selection is based on the fact that the abnormality of the parameter has a certain impact on the normal conduct of the diesel engine bench test, but there is no risk of damage to the diesel engine, personnel, laboratory and equipment. The normal value upper limit array (14) is used to store the upper limit value of each alarm parameter channel for each diesel engine test condition; An engine operating condition array (15) is used to store each diesel engine test operating condition; The normal value lower limit array (16) is used to store the lower limit value of each alarm parameter channel for each diesel engine test condition; The extreme parameter alarm handling strategy (17) is triggered when the extreme parameter alarm occurs. The handling strategy is to reduce the diesel engine idle speed and the dynamometer enters the idle mode. The processing strategy for important parameter alarms (18) is triggered when an important parameter alarm occurs. The processing strategy is to make a buzzer sound and turn the alarm parameter font white to serve as a reminder. It does not operate the dynamometer or diesel engine. The processing strategy for routine parameter alarms (19) is triggered when a routine parameter alarm occurs. The processing strategy is that the buzzer does not sound, only the alarm parameter font turns white to serve as a reminder, and there is no operation on the dynamometer and diesel engine. The third data storage module (20) is used to store data from the classification alarm system (13); The first data storage module (3), the second data storage module (7), and the third data storage module (20) are stored in parallel.

2. The automatic monitoring and alarm system for diesel engine performance status during durability bench testing as described in claim 1, characterized in that, The tested diesel engine (1) is a high-pressure common rail turbocharged intercooled four-stroke diesel engine, an inline pump turbocharged intercooled four-stroke diesel engine, or a unit pump turbocharged intercooled four-stroke diesel engine.

3. The automatic monitoring and alarm system for diesel engine performance status during durability bench testing as described in claim 1, characterized in that, The first data storage module (3) is used to store the full-channel data of the bench data acquisition system (2). The storage method is sequential storage. The storage marker is: the file name starts with 1-. The storage condition is: storage starts when the test begins and stops when the test ends. The storage frequency is 2Hz. The storage file type is excel. The storage location is: the hard disk of the hardware platform on which the bench data acquisition system (2) runs.

4. The automatic monitoring and alarm system for diesel engine performance status during durability bench testing as described in claim 1, characterized in that, The data interaction module (5) sets the CAN communication parameters of the online statistical system (4) for the entire durability test cycle, including CAN card selection, CAN card enable and disable, and baud rate setting. On the other hand, it reads the test data from the bench data acquisition system (2) and parses the read messages into decimal numerical form for easy display and storage.

5. The automatic monitoring and alarm system for diesel engine performance status during durability bench testing as described in claim 1, characterized in that, The second data storage module (7) stores real-time test data from the communication between the bench data acquisition system (2) and the online statistical system for the entire durability test cycle (4) using a push-and-pop method. The design of the stack 2 cache size is 10.5MB, which meets the data storage capacity of 5min, 100Hz frequency, and 100 channels. When the storage file cache is less than 10.5MB, the data is stored into the file in sequence. When the storage file cache reaches 10.5MB, the data stored later will push out the data stored earlier. Storage mark: 3rd storage file; Storage channel: The channel contained in the real-time test data from the communication between the bench data acquisition system (2) and the online statistical system for the entire durability test cycle (4); Storage condition: If the communication between the bench data acquisition system (2) and the online statistical system for the entire durability test cycle (4) is established, storage will start; otherwise, storage will stop; Storage frequency: 2Hz; Storage file type: excel; Storage location: Hard disk of the hardware platform on which the online statistical system for the entire durability test cycle (4) runs.

6. The automatic monitoring and alarm system for diesel engine performance status during durability bench testing as described in claim 5, characterized in that, When the second data storage module (7) calculates the average test data in the online statistical system (4) for the entire durability test cycle, if there are a total of 4 operating conditions in the engine durability test, there are a total of 5 storage files. The first storage file is the data stored in real time for 5 minutes. The second storage file is the average value calculated after every 5 minutes of operation in engine durability test condition 1. The third storage file is the average value calculated after every 5 minutes of operation in engine durability test condition 2. The fourth storage file is the average value calculated after every 5 minutes of operation in engine durability test condition 3. The fifth storage file is the average value calculated after every 5 minutes of operation in engine durability test condition 4.

7. The automatic monitoring and alarm system for diesel engine performance status during durability bench testing as described in claim 6, characterized in that, When the engine is conducting a normal durability test, firstly, the second data storage module (7) creates a full-channel 5-minute storage space with an excel file type, a storage frequency of 2Hz, and a location on the hard disk of the hardware platform where the online statistical system (4) for the entire durability test cycle is running; Secondly, after the diesel engine runs continuously for 5 minutes under a certain working condition, the average value of 600 sampling points in each channel within 5 minutes is processed. Finally, the average value is classified and stored in the storage file corresponding to the working condition according to the engine operating condition. The storage file is located in the hard disk of the hardware platform of the online statistical system (4) running the durability full test cycle. When an engine experiences an abnormality during a durability test, i.e., the operating condition lasts less than 5 minutes, the average value calculated based on the actual duration is stored in the corresponding operating condition storage file.

8. The automatic monitoring and alarm system for diesel engine performance status during durability bench testing as described in claim 7, characterized in that, Based on the engine operating conditions, when a certain operating condition has been running for 5 minutes, the average value of the data in stack 2 is calculated. If the engine needs to switch operating conditions, and the operating condition does not meet the 5-minute duration, the average value is still calculated based on the actual duration. Each average value is stored in the order of engine operating time. Storage mark: Based on the engine durability test conditions, the diesel engine durability test has a total of 9 sub-cycles. Among them, 5 sub-cycles have short working times and are not counted. The remaining 4 operating conditions have long running times. The 4 operating conditions are: Operating condition 1, the speed is 100% of the marked speed, the torque is executed according to the external characteristics, and the running time is 60 minutes. Operating condition 2: The speed is 85% to 90% of the marked speed, the torque is executed according to the external characteristics, and the running time is 420 minutes; Operating condition 3: The speed is 80% of the marked speed, the torque is executed according to the external characteristics, and the running time is 100 minutes. Condition 4's engine speed corresponds to the maximum torque, and the torque value is the maximum torque. The operating time is 20 minutes, and the duration of each condition is a multiple of 5 minutes. Four storage files are created: 4-Condition 1, 4-Condition 2, 4-Condition 3, and 4-Condition 4. The data stored in storage file 4-Condition 1 is the average value calculated after every 5 minutes of operation in Condition 1 of the engine durability test. The data stored in storage file 4-Condition 2 is the average value calculated after every 5 minutes of operation in Condition 2 of the engine durability test. The data stored in storage file 4-Condition 3 is the average value calculated after every 5 minutes of operation in Condition 2 of the engine durability test. The average value calculated after every 5 minutes of operation in condition 3; the data stored in the storage file of condition 4 is the average value calculated after every 5 minutes of operation in condition 4 of the engine durability test; storage channel: the channel containing the real-time test data communicated between the bench data acquisition system (2) and the online statistical system (4) for the entire durability test cycle; storage conditions: when a certain condition runs continuously for 5 minutes or when switching conditions for less than 5 minutes; storage frequency: once every 5 minutes or when switching conditions; storage file type: excel; storage location: the hard disk of the hardware platform on which the online statistical system (4) for the entire durability test cycle runs.

9. The automatic monitoring and alarm system for diesel engine performance status during durability bench testing as described in claim 1, characterized in that, The parameters involved in the extreme parameter alarm list (10) include: diesel engine speed, diesel engine torque, diesel engine fuel consumption and turbocharger speed; the parameters involved in the important parameter alarm list (11) include: main oil passage pressure, water pump after pressure, low pressure oil pump after fuel pressure, engine oil inlet temperature, engine water inlet temperature, fuel inlet temperature, exhaust gas pressure and turbine exhaust temperature; the parameters involved in the regular parameter alarm list (12) include: engine intake air temperature and engine intake air pressure.

10. The automatic monitoring and alarm system for diesel engine performance status during durability bench testing as described in claim 1, characterized in that, The third data storage module (20) uses the following storage method: push-in and pop-out. The design of the stack 1 cache size is 21MB, which meets the data storage capacity of 10min, 100hz frequency, and 100 channels. The storage marker is: the file name starts with 2-. The storage channel is: all channels of the bench data acquisition system. The storage conditions are: when the data acquisition system starts working, stack 1 is created. When a certain channel in the alarm parameter table (9) triggers the alarm upper or lower limit, the data in the time period of 5min before and 5min after the alarm is read from stack 1. The test data in other time periods is not read. The "2-Channel Alarm-Time" file is formed and stored. If multiple channels trigger the alarm upper or lower limit at the same time, multiple "2-Channel Alarm-Time" files are formed and stored. If the time interval between two alarms is less than 5min, "2-Channel Alarm-Time" files are formed and stored. No other operations are performed on the data in the stack. The storage frequency is 2Hz. The storage file type is excel. The storage location is the hard disk of the hardware platform on which the bench data acquisition system runs.

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