Cooling system and method for diesel-electric power pack of small unmanned vehicle in laboratory environment

Abstract

The invention provides a heat dissipation test system and method for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment, and the system is characterized in that a heat dissipation system composed of a high-temperature cycle, a low-temperature cycle and an intercooler cycle is connected with a cooling system of an engine, a generator and a generator controller in the power pack; the connection mode can be adjusted according to different heat dissipation requirements, the high-temperature circulation is used for cooling the engine, the low-temperature circulation is used for cooling the generator and a controller of the generator, the intercooler circulation is used for cooling an intercooler of the engine, and each circulation exchanges heat with a corresponding cooling water path through a water-water heat exchanger or a water-air heat exchanger; a temperature sensor and a flow sensor are installed in each cooling circulation path, measured data are transmitted to an upper computer or a data collector through current or voltage signals, and real-time monitoring and data feedback of the cooling system are achieved. According to the scheme, the heat dissipation condition of the power pack under the actual working condition is fully simulated, and accurate data support is provided for subsequent optimization design.

Description

Technical Field

[0001] The present invention belongs to the field of vehicle engineering / experimental testing, and in particular relates to a heat dissipation system and method for a diesel-electric power pack of a small unmanned vehicle in a laboratory environment. Background Art

[0002] In the initial design stage, the installation positions of the various system components of the power pack are difficult to determine due to mission requirements, space limitations, etc., and the resulting heat dissipation is difficult to evaluate, making it impossible to determine the parameters of the heat dissipation system. In addition, due to production schedules, product characteristics, etc., the heat dissipation system of the power pack may not have the test conditions. At this time, the laboratory is in urgent need of providing a heat dissipation system with universal dimensions that can meet the power of various power packs for testing. At the same time, in the actual testing process, in order to better grasp the heat dissipation characteristics of each system in different parts, the test usually also needs to measure the heat flow data of the power pack under various working conditions, that is, the inlet and outlet coolant temperature and flow rate of each heat dissipation cycle, so as to calculate and evaluate the heat generation power of the system components. The arrangement of measuring points on the molded power pack is bound to damage the original pipeline. At the same time, frequent disassembly and assembly will also lead to safety hazards and material corrosion caused by reduced sealing performance and leakage at the pipeline joints.

[0003] In addition, the PID control of the cooling system currently performed only through temperature sensors generally has problems such as low sensitivity, long response time, and low measurement accuracy. During the power pack test, there is also a corresponding demand for the measurement of this part.

[0004] The heat generated by the power pack during operation will be carried to the radiator through the coolant for circulation and heat dissipation. Figure 1 As shown, the heat dissipation cycle is usually divided into a high-temperature heat dissipation cycle (mainly including the engine) and a low-temperature cycle (mainly including the generator, engine controller, etc.) according to the heat dissipation power and designed separately to achieve optimal heat dissipation performance.

[0005] In the process of developing the existing small power units for unmanned vehicles in my country, a lot of test verification is required to improve the design before the next demonstration stage can be carried out, and even the whole vehicle design can be completed. The data obtained during the test will be different from the theoretical calculated values. At this time, the designer needs to make corresponding corrections to the parameters with deviations and re-optimize the design. Therefore, the early test process is of great significance to the entire design stage. The power pack itself has a compact structure, and the placement of each system component has strict requirements, which requires rigorous calculation and design. In the early stage of the entire design process, the overall layout of the power pack cannot be finalized due to the difficulty in determining the various parameters of the system, so the position and specifications of the radiator cannot be directly determined. If the radiator power is increased, the radiator size will increase, which will be difficult to meet the overall size requirements, and the space of other systems will be squeezed, making it difficult to assemble; if the radiator power is insufficient, it will not meet the heat dissipation requirements of the system, making it impossible for each system to achieve the expected function. Although the radiator can be used to meet the heat dissipation requirements according to the calculated value, there will be repeated disassembly and assembly and material loss during the design optimization process, which will consume manpower and material resources, which will not only affect the project progress, but also cause unnecessary waste. In addition, there are also high requirements for the accuracy and comprehensiveness of the data. Summary of the invention

[0006] In view of this, the present invention provides a heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment, wherein a heat dissipation system consisting of a high temperature cycle, a low temperature cycle and an intercooler cycle is connected to the cooling system of the engine, the generator and the generator controller in the power pack, and the connection method can be adjusted according to different heat dissipation requirements.

[0007] The high temperature cycle is used to cool the engine, the low temperature cycle is used to cool the generator and its controller, and the intercooler cycle is used to cool the intercooler of the engine. Each cycle exchanges heat with the corresponding cooling water circuit through a water-water heat exchanger or a water-air heat exchanger;

[0008] Temperature sensors and flow sensors are installed in each cooling cycle path, and the measurement data is transmitted to the host computer or data collector through current or voltage signals to achieve real-time monitoring and data feedback of the cooling system.

[0009] In particular, in the heat dissipation system, the heat exchanger corresponding to the intercooler is a water-to-air heat exchanger, and the remaining heat exchangers are water-to-water heat exchangers.

[0010] In particular, the host computer integrates a PID control program to automatically adjust the throttle valve opening and the electric heater power according to the set value and the feedback temperature and flow data, and automatically adjust the flow and temperature of the cooling water.

[0011] In particular, an electric heater is installed in the water circuit of the cooling system, and a high-precision PT100 temperature sensor is used to perform temperature compensation on the cooling water.

[0012] In particular, each component of the heat dissipation system adopts a standard interface, and all connecting parts are designed to be detachable, so that they can be quickly removed after the test is completed to facilitate replacement of the power pack to be tested.

[0013] The present invention also discloses a method for a heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment, comprising the following steps:

[0014] Step 1, connecting a high temperature cycle, a low temperature cycle and an intercooler cycle with corresponding cooling systems of the power pack;

[0015] Step 2, open the main valve of the cooling water circuit, fully open the throttle valve, and ensure that the cooling water in the circulating water circuit is in a flowing state;

[0016] Step 3: Check whether the temperature sensors and flow sensors at each measuring point are connected to the host computer or data collector online to ensure reliable data transmission;

[0017] Step 4: Start the power pack and issue a specified power command after the unit is warmed up;

[0018] After the power is stable, observe and record the values ​​of each temperature sensor and flow sensor, and compare them with the target values;

[0019] Use the host computer to reduce the opening of the throttle valve and observe whether the flow sensor shows a decrease in the cooling water flow; use the host computer to start and set the working power of the electric heater and observe whether the temperature sensor shows an increase in the cooling water temperature;

[0020] Step 5, start the PID control program, manually increase the throttle valve opening, observe whether the electric heater increases the working power accordingly to check whether the throttle valve and the electric heater are working normally, manually adjust or set the control parameters of the PID control program, and automatically adjust the equilibrium temperature.

[0021] In particular, the automatic adjustment of the equilibrium temperature includes: a PID control program controls the throttle valve to change the opening to adjust the cooling water flow according to the deviation between the set temperature value and the actual temperature value fed back;

[0022] The PID control program also controls the electric heater to change the heating power according to the temperature deviation and performs temperature compensation on the cooling water.

[0023] In particular, during the operation, the host computer displays the temperature and flow data of each measuring point in real time and stores the data for subsequent analysis.

[0024] Beneficial effects:

[0025] 1. A comprehensive simulation test of the power pack cooling system has been achieved, including high-temperature cycle, low-temperature cycle and intercooler cycle, which can fully simulate the heat dissipation of the power pack under actual working conditions and provide accurate data support for subsequent optimization design.

[0026] 2. Standardized modular design is adopted, and all components are connected by universal interfaces, which facilitates module replacement and system expansion, making the test bench highly adaptable and able to meet the testing requirements of power packs of different specifications and power levels.

[0027] 3. The integrated automatic PID control program can automatically adjust the throttle valve opening and electric heater power according to the set value and sensor feedback data, so as to achieve precise control of cooling water temperature and flow rate, and the temperature measurement accuracy can reach above 0.1℃.

[0028] 4. All connecting parts adopt quick connection method and can be quickly disassembled and assembled without using tools, which greatly shortens the time of replacing the power pack under test and improves work efficiency.

[0029] 5. The host computer monitors and stores the temperature, flow and other parameter data of each measuring point in real time, providing a complete record for subsequent data analysis and heat flow calculation, which is helpful for in-depth research and optimization of thermal balance design.

[0030] 6. The entire system does not require special customization for its construction and use, and can quickly carry out initial heat dissipation and heat flow tests on the power pack, saving time and money for the entire R&D process. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 This is a schematic diagram of the heat dissipation system principle;

[0032] Figure 2 A schematic diagram of a heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment of the present invention;

[0033] Figure 3 The present invention is a method flow diagram of a heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment. DETAILED DESCRIPTION

[0034] The present invention is described in detail below with reference to the accompanying drawings and embodiments.

[0035] The present invention provides a heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment, wherein a heat dissipation system consisting of a high-temperature cycle, a low-temperature cycle and an intercooler cycle is connected to the cooling system of the engine, the generator and the generator controller in the power pack, and the connection method can be adjusted according to different heat dissipation requirements. High-temperature cycle: mainly includes the engine cooling water circuit, and the outlet water temperature is about 100°C when the power pack is in high-power operation;

[0036] Low temperature cycle: including generator, generator controller, etc., the outlet water temperature is about 70℃;

[0037] Intercooler: dissipate heat from the engine intercooler, and the target cooling medium is air;

[0038] Power pack: The main heat dissipation components in the thermal balance test and heat flow test include the engine, generator, engine controller, intercooler, etc. The connection can be completed by connecting the water line to the water-water and water-air heat exchanger pipes. When the test is completed, disconnect the connection and transport / replace the power pack to be tested.

[0039] The high temperature cycle is used to cool the engine, the low temperature cycle is used to cool the generator and its controller, and the intercooler cycle is used to cool the intercooler of the engine. Each cycle exchanges heat with the corresponding cooling water circuit through a water-water heat exchanger or a water-air heat exchanger;

[0040] In the cooling system, the heat exchanger corresponding to the intercooler is a water-to-air heat exchanger, and the other heat exchangers are water-to-water heat exchangers. Heat is exchanged with the corresponding cycles at the heat exchangers and then flows out.

[0041] Temperature sensors and flow sensors are installed in each cooling cycle path, and the measurement data is transmitted to the host computer or data collector through current or voltage signals to achieve real-time monitoring and data feedback of the cooling system.

[0042] Temperature sensor: To monitor the cooling water circuit, a model with high sensitivity and accuracy should be selected as much as possible. The measured value is transmitted to the host computer or data acquisition device through the output current or voltage signal;

[0043] Flow sensor: monitors the cooling water flow and transmits the measured value to the host computer or data acquisition device through output current or voltage signal;

[0044] Electric heater: Heat the cooling water through the set value and switch to achieve temperature compensation to accurately adjust the cooling water to the target temperature. The measurement accuracy of the PT100 temperature sensor with Class A accuracy on the market is about 0.2℃, and the measurement accuracy can be increased to more than 0.1℃ with the electric heater;

[0045] Throttle valve: controls the opening by receiving electrical signals to adjust the water flow in the cooling water circuit. It can be manually adjusted by the host computer control, or the entire circuit can be PID controlled by the inlet and outlet temperature values ​​and the water circuit flow value to achieve the purpose of automatic adjustment.

[0046] The host computer integrates PID control program, which automatically adjusts the throttle valve opening and electric heater power according to the set value and feedback temperature and flow data, and automatically adjusts the flow and temperature of the cooling water.

[0047] An electric heater is installed in the water circuit of the cooling system, and a high-precision PT100 temperature sensor is used to compensate the temperature of the cooling water.

[0048] All components of the heat dissipation system adopt standard interfaces, and all connecting parts are designed to be detachable, so they can be quickly removed after the test is completed to facilitate replacement of the power pack to be tested.

[0049] The present invention also discloses a method for a heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment, comprising the following steps:

[0050] Step 1, connecting a high temperature cycle, a low temperature cycle and an intercooler cycle with corresponding cooling systems of the power pack;

[0051] Step 2, open the main valve of the cooling water circuit, fully open the throttle valve, and ensure that the cooling water in the circulating water circuit is in a flowing state;

[0052] Step 3: Check whether the temperature sensors and flow sensors at each measuring point are connected to the host computer or data collector online to ensure reliable data transmission;

[0053] Step 4: Start the power pack and issue a specified power command after the unit is warmed up;

[0054] After the power is stable, observe and record the values ​​of each temperature sensor and flow sensor, and compare them with the target values;

[0055] Use the host computer to reduce the opening of the throttle valve and observe whether the flow sensor shows a decrease in the cooling water flow; use the host computer to start and set the working power of the electric heater and observe whether the temperature sensor shows an increase in the cooling water temperature;

[0056] Step 5, start the PID control program, manually increase the throttle valve opening, observe whether the electric heater increases the working power accordingly to check whether the throttle valve and the electric heater are working normally, manually adjust or set the control parameters of the PID control program, and automatically adjust the equilibrium temperature.

[0057] The automatic adjustment of the equilibrium temperature includes: the PID control program controls the throttle valve to change the opening to adjust the cooling water flow according to the deviation between the set temperature value and the actual temperature value fed back;

[0058] The PID control program also controls the electric heater to change the heating power according to the temperature deviation and performs temperature compensation on the cooling water.

[0059] During the operation, the host computer displays the temperature and flow data of each measuring point in real time and stores the data for subsequent analysis.

[0060] In summary, the above are only preferred embodiments of the present invention and are not intended to limit the protection scope of the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

[0061] It is obvious to those skilled in the art that the embodiments of the present invention are not limited to the details of the above exemplary embodiments, and that the embodiments of the present invention can be implemented in other specific forms without departing from the spirit or basic features of the embodiments of the present invention. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-restrictive, and the scope of the embodiments of the present invention is limited by the attached claims rather than the above description, so it is intended to include all changes that fall within the meaning and scope of the equivalent elements of the claims in the embodiments of the present invention. Any figure mark in the claims should not be regarded as limiting the claims involved. In addition, it is obvious that the word "comprising" does not exclude other units or steps, and the singular does not exclude the plural. Multiple units, modules or devices stated in the system, device or terminal claims can also be implemented by the same unit, module or device through software or hardware. The words first, second, etc. are used to indicate names, and do not indicate any particular order.

[0062] Finally, it should be noted that the above implementation modes are only used to illustrate the technical solutions of the embodiments of the present invention and are not intended to limit them. Although the embodiments of the present invention have been described in detail with reference to the above preferred implementation modes, those skilled in the art should understand that the technical solutions of the embodiments of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment, wherein a heat dissipation system consisting of a high temperature cycle, a low temperature cycle and an intercooler cycle is connected to the cooling system of the engine, the generator and the generator controller in the power pack, and the connection method can be adjusted according to different heat dissipation requirements. Features: The high temperature cycle is used to cool the engine, the low temperature cycle is used to cool the generator and its controller, and the intercooler cycle is used to cool the intercooler of the engine. Each cycle exchanges heat with the corresponding cooling water circuit through a water-water heat exchanger or a water-air heat exchanger; Temperature sensors and flow sensors are installed in each cooling cycle path, and the measurement data is transmitted to the host computer or data collector through current or voltage signals to achieve real-time monitoring and data feedback of the cooling system.

2. The heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment as claimed in claim 1, Features: In the cooling system, the heat exchanger corresponding to the intercooler is a water-to-air heat exchanger, and the other heat exchangers are water-to-water heat exchangers.

3. The heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment as claimed in claim 2, Features: The host computer integrates PID control program, which automatically adjusts the throttle valve opening and electric heater power according to the set value and feedback temperature and flow data, and automatically adjusts the flow and temperature of the cooling water.

4. The heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment as claimed in claim 3, Features: An electric heater is installed in the water circuit of the cooling system, and a high-precision PT100 temperature sensor is used to compensate the temperature of the cooling water.

5. The heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment as claimed in claim 4, Features: All components of the heat dissipation system adopt standard interfaces, and all connecting parts are designed to be detachable, so they can be quickly removed after the test is completed to facilitate replacement of the power pack to be tested.

6. A method for a heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment as claimed in any one of claims 1 to 5, It is characterized in that The following steps are involved: Step 1, connecting a high temperature cycle, a low temperature cycle and an intercooler cycle with corresponding cooling systems of the power pack; Step 2, open the main valve of the cooling water circuit, fully open the throttle valve, and ensure that the cooling water in the circulating water circuit is in a flowing state; Step 3: Check whether the temperature sensors and flow sensors at each measuring point are connected to the host computer or data collector online to ensure reliable data transmission; Step 4: Start the power pack and issue a specified power command after the unit is warmed up; After the power is stable, observe and record the values ​​of each temperature sensor and flow sensor, and compare them with the target values; Use the host computer to reduce the opening of the throttle valve and observe whether the flow sensor shows a decrease in the cooling water flow; use the host computer to start and set the working power of the electric heater and observe whether the temperature sensor shows an increase in the cooling water temperature; Step 5, start the PID control program, manually increase the throttle valve opening, observe whether the electric heater increases the working power accordingly to check whether the throttle valve and the electric heater are working normally, manually adjust or set the control parameters of the PID control program, and automatically adjust the equilibrium temperature.

7. The method of the heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment as claimed in claim 6, It is characterized in that The automatic adjustment of the equilibrium temperature includes: the PID control program controls the throttle valve to change the opening to adjust the cooling water flow according to the deviation between the set temperature value and the actual temperature value fed back; The PID control program also controls the electric heater to change the heating power according to the temperature deviation and performs temperature compensation on the cooling water.

8. The method of the heat dissipation test system for testing a diesel-electric power pack of a small unmanned vehicle in a laboratory environment as claimed in claim 7, It is characterized in that During the operation, the host computer displays the temperature and flow data of each measuring point in real time and stores the data for subsequent analysis.

Images