An aircraft engine hybrid power test control system

Abstract

The present application discloses a hybrid power test control system for an aircraft engine, including: a fast switching device, which is respectively connected to the engine, generator, rectifier, and each load system circuit; an emergency protection load system, which is connected to the fast switching device circuit; a first and a second test system, which are respectively used for collecting and storing the state parameters of the engine and collecting and storing the state data of the generator, rectifier, and each load system and transmitting them to the electrical control system; a filter, which is used to suppress electromagnetic interference; a control system, which is respectively connected to the engine EEC and the electrical control system circuit; an electrical control system, which is respectively connected to the EEC, the control system, auxiliary equipment, the fast switching device, and each load system circuit; a PROFINET system network, which uses the PROFINET protocol for fast data exchange. The present application adopts a systematic design to avoid independent design defects, which can not only achieve the reliability of test control, but also greatly reduce the safety risk of the test.

Description

Technical Field

[0001] The present application relates to the technical field of aircraft engines, and in particular, to an aircraft engine hybrid power test control system. Background Art

[0002] The principles and components of the existing hybrid test system are as follows: Figure 1 As shown, it includes the prime mover (aircraft engine), generator, rectifier, load system, platform electrical control, power generation control host computer, load control host computer, etc. The aircraft engine is the prime mover, and its output shaft drives the generator. The engine generates AC power after electromagnetic conversion, which is stabilized by the rectifier and output to the resistive load for consumption and power balance. The platform electrical control is mainly used to control the start and stop of the engine and status monitoring, the generator control host computer is mainly used for monitoring the power generation part, and the load control host computer is mainly used for parameter monitoring and load addition and reduction operations of the load system.

[0003] Obviously, the existing hybrid test system has a decentralized control design, which includes vehicle electrical control, power generation system monitoring, and load control. Due to the decentralized and independent design of each part, data blockage and uncentralized monitoring, not only does it cause a waste of test personnel and low system test efficiency, but more importantly, the test safety risk cannot be guaranteed. In particular, the original design did not consider that when the engine is in a high state, if the load is suddenly lost, it will cause the engine to run away, the turbine blades will break and be thrown out, causing serious test safety accidents. Summary of the invention

[0004] The present application provides an aircraft engine hybrid power test control system to solve the technical problem that the existing aircraft engine hybrid power system has no overspeed protection function during the test, and the test has great safety risks.

[0005] The technical solutions adopted in this application are as follows:

[0006] An aircraft engine hybrid power test control system, comprising:

[0007] A fast switching device is respectively connected to the engine, the generator, the rectifier, the DC load system, and the emergency protection load system circuits, and is used to quickly disconnect the DC load system and switch the DC load system to the emergency protection load system when it is detected that the hybrid power system is in a large state and a DC load loss fault occurs;

[0008] An emergency protection load system is connected to the fast switching device circuit and is used to provide an emergency protection load when the hybrid power system is in a large state and a DC load loss failure occurs, so as to avoid the engine overspeed during the test causing the turbine blade to break;

[0009] The first test system and the second test system are respectively used for collecting and storing the state parameters of the engine and the state data of the generator, rectifier and various load systems, and transmitting them to the electrical control system;

[0010] A filter, which is arranged in a loop between the rectifier and the DC load system and is used to suppress electromagnetic interference;

[0011] The control system is connected to the EEC and electrical control system circuits of the engine respectively, and is used to send the control instructions during the test to the electrical control system and EEC, and to centrally monitor the operating status, real-time data, alarm status and control instructions of each subsystem transmitted to the electrical control system through the host computer;

[0012] The electrical control system is connected to the EEC, the control system, the auxiliary equipment, the fast switching device, the emergency protection load system, the DC load system, and the generator circuit respectively, and is used to realize the power supply and control of the EEC, the monitoring of the generator, the power supply and control of each load, and the power supply and monitoring of the auxiliary equipment according to the control instructions sent by the control system;

[0013] The PROFINET system network uses the PROFINET protocol for fast data exchange, which is used to realize real-time fast data exchange between the operating system and the electrical control system, as well as data communication between the electrical control system and the fast switching device, DC load system, emergency protection load system, first test system and second test system, and auxiliary equipment.

[0014] Furthermore, the fast switching device comprises:

[0015] The fast switching unit is respectively connected to the generator, the rectifier and the emergency protection load system circuit, and is used to quickly disconnect the DC load system and switch the DC load system to the emergency protection load system according to the switching instruction issued by the controller;

[0016] The measuring unit is respectively connected with the engine, the generator, the rectifier, and the DC load system circuit, and is used to measure the engine gas turbine speed, the free turbine speed, the AC voltage and current, the DC voltage and current, the rectifier fault digital signal, and the DC load system fault digital signal;

[0017] The controller is connected to the fast switching unit, the measuring unit and the monitoring system circuit respectively, and is used to make fault judgment according to the measurement data collected by the measuring unit and send a switching instruction to the fast switching unit accordingly when a fault occurs.

[0018] Furthermore, the fast switching unit includes a switching switch, which includes an IGPT switching normally open switch and an IGPT switching normally closed switch. The IGPT switching normally open switch and the IGPT switching normally closed switch are respectively connected to the emergency protection load system and the rectifier to form an interlocking relationship.

[0019] Furthermore, the fast switching unit includes a switching switch, which includes a normally open high-power solid-state relay and a normally closed high-power solid-state relay. The normally open high-power solid-state relay and the normally closed high-power solid-state relay are respectively connected to the emergency protection load system and the rectifier to form an interlocking relationship.

[0020] Furthermore, the load size of the emergency protection load system is consistent with that of the DC load system.

[0021] Furthermore, the emergency protection load system includes: air-cooled AC load, air-cooled DC load with rectifier, air-cooled AC load, air-cooled DC load with rectifier, water-cooled AC load, water-cooled DC load with rectifier, electric dynamometer, eddy current dynamometer, and grid-connected load.

[0022] Further, the method of performing fault judgment on the system according to the measurement data collected by the measurement unit and issuing a switching instruction to the fast switching unit accordingly when a fault occurs specifically includes the steps of:

[0023] Acquire measurement data collected by the measurement unit, including gas turbine speed, free turbine speed, AC voltage, and AC current;

[0024] When the engine is in a set power state above the air idle, if a fault is detected, a switching instruction is immediately sent to the fast switching unit for protection. The set power state is specifically a state of more than 80% of the full power of the engine.

[0025] Furthermore, when the engine is in a set power state above the air idle, if a fault is detected, a switching instruction is immediately sent to the fast switching unit for protection, specifically including the steps of:

[0026] Engine status judgment: When the gas turbine speed ≥ A, free turbine speed = B, AC voltage ≥ C, AC current ≥ G, the engine is judged to be in a set power state above the air idle, where A is the minimum set value of the gas turbine speed; B is the set value of the free turbine speed; C is the minimum set value of the generator output AC voltage; G is the minimum set value of the generator output AC current;

[0027] Fault judgment: If the DC current ≤ H, or the DC voltage ≤ J, or a rectifier fault digital signal is received, or a DC load system fault digital signal is received, it is considered to be a fault, where H is the minimum setting value of the DC current, and J is the minimum setting value of the DC voltage;

[0028] Send command: immediately send a switching command to the fast switching unit for protection.

[0029] Furthermore, the electrical control system adopts PLC as the central processor, adopts a distributed I / O architecture, uses the PROFINET protocol for data exchange, and realizes control instruction input and output and data acquisition functions through DI, DO, AI, and AO communication modules.

[0030] Furthermore, the control system includes a button indicator light, an emergency stop button, a warning light, a host computer, and a throttle lever. The emergency stop button and warning light are used for emergency stop and sound and light alarm, respectively; the throttle lever is used to give the loading power of the DC load system and send an RVDT signal to the EEC at the same time, forming a control mode of the throttle lever linkage load and the engine; the host computer is used to centrally remotely monitor the operating status, real-time data, alarm status and operating instructions of each subsystem transmitted to the electrical control system.

[0031] Compared with the prior art, this application has the following beneficial effects:

[0032] The present application provides an aircraft engine hybrid power test control system, including a fast switching device, an emergency protection load system, a first test system and a second test system, a filter, a control system, an electrical control system, and a PROFINET system network. On the one hand, the present application uses a systematic design, a distributed control, and a centralized monitoring method, and uses the PROFINET system network to ensure reliable signal function control and fast data exchange, so as to improve the system test efficiency. On the other hand, the present application realizes controllable test risks through a fast switching device and an emergency protection load system, which can quickly disconnect the DC load system and switch the DC load system to the emergency protection load system when the DC load suddenly fails to unload abnormally when the engine is in a large state, so as to avoid the abnormal increase of the engine speed causing the centrifugal force of the blade to exceed the limit, and realize the overspeed protection of the engine hybrid power system test, so as to avoid the test accident of the turbine blade breaking and flying out; on the third aspect, the present application considers the faults of the engine, the generator rectifier, the DC load system, the fast switching device, etc. as a whole, monitors the working status of each system in real time, and handles the fault or alarm in time if there is a fault, so as to maximize the controllable test risk. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The drawings constituting a part of the present application are used to provide a further understanding of the present application. The illustrative embodiments and descriptions of the present application are used to explain the present application and do not constitute an improper limitation on the present application. In the drawings:

[0034] Figure 1 It is a schematic diagram of the principle of the aircraft engine test system.

[0035] Figure 2 It is a schematic diagram of the principle of an aircraft engine hybrid power test control system according to a preferred embodiment of the present application.

[0036] Figure 3 It is the software layered architecture of the fast switching emergency protection system of the preferred embodiment of the present application. DETAILED DESCRIPTION

[0037] The embodiments of the present application are described in detail below in conjunction with the accompanying drawings, but the present application can be implemented in a variety of different ways defined and covered below.

[0038] like Figure 2 As shown, the preferred embodiment of the present application provides an aircraft engine hybrid power test control system, comprising:

[0039] A fast switching device is respectively connected to the engine, the generator, the rectifier, the DC load system, and the emergency protection load system circuits, and is used to quickly disconnect the DC load system and switch the DC load system to the emergency protection load system when it is detected that the hybrid power system is in a large state (the engine gas turbine speed is greater than 80%) and a DC load loss fault occurs;

[0040] An emergency protection load system is connected to the fast switching device circuit and is used to provide an emergency protection load when the hybrid power system is in a large state and a DC load loss failure occurs, so as to avoid the engine overspeed during the test causing the turbine blade to break;

[0041] The first test system and the second test system are respectively used for collecting and storing the state parameters of the engine and the state data of the generator, rectifier and various load systems, and transmitting them to the electrical control system;

[0042] A filter, which is arranged in a loop between the rectifier and the DC load system and is used to suppress electromagnetic interference;

[0043] The control system is connected to the EEC (electronic engine controller) and the electrical control system circuit of the engine, and is used to send the control instructions during the test to the electrical control system and EEC, and to centrally monitor the operating status, real-time data, alarm status and control instructions of each subsystem transmitted to the electrical control system through the host computer;

[0044] The electrical control system is connected to the EEC, the control system, the auxiliary equipment, the fast switching device, the emergency protection load system, the DC load system, and the generator circuit respectively, and is used to realize the power supply and control of the EEC, the monitoring of the generator, the power supply and control of each load, and the power supply and monitoring of the auxiliary equipment according to the control instructions sent by the control system;

[0045] The PROFINET system network uses the PROFINET protocol for fast data exchange, which is used to realize real-time fast data exchange between the operating system and the electrical control system, as well as data communication between the electrical control system and the fast switching device, DC load system, emergency protection load system, first test system and second test system, and auxiliary equipment.

[0046] The present embodiment provides an aircraft engine hybrid power test control system, including a fast switching device, an emergency protection load system, a first test system and a second test system, a filter, a control system, an electrical control system, and a PROFINET system network. On the one hand, the present embodiment uses a systematic design, a distributed control, and a centralized monitoring method, and uses the PROFINET system network to ensure reliable signal function control and fast data exchange, thereby improving the system test efficiency. On the other hand, the present embodiment realizes controllable test risks through a fast switching device and an emergency protection load system, which can quickly disconnect the DC load system and switch the DC load system to the emergency protection load system when the DC load suddenly abnormally unloads when the engine is in a large state, so as to avoid the abnormal increase of the engine speed causing the centrifugal force of the blade to exceed the limit, and realize overspeed protection for the engine hybrid power system test, so as to avoid the test accident of the turbine blade breaking and flying out; thirdly, the present embodiment considers the faults of the engine, the generator rectifier, the DC load system, the fast switching device, etc. from the overall perspective, monitors the working status of each system in real time, and handles the faults or alarms in time, so as to maximize the controllable test risks.

[0047] Preferably, the fast switching device comprises:

[0048] The fast switching unit is respectively connected to the generator, the rectifier and the emergency protection load system circuit, and is used to quickly disconnect the DC load system and switch the DC load system to the emergency protection load system according to the switching instruction issued by the controller;

[0049] The measuring unit is respectively connected with the engine, the generator, the rectifier, and the DC load system circuit, and is used to measure the engine gas turbine speed, the free turbine speed, the AC voltage and current, the DC voltage and current, the rectifier fault digital signal, and the DC load system fault digital signal;

[0050] The controller is connected to the fast switching unit, the measuring unit and the monitoring system circuit respectively, and is used to make fault judgment according to the measurement data collected by the measuring unit and send a switching instruction to the fast switching unit accordingly when a fault occurs. The controller adopts a NICRIO controller.

[0051] There are gas turbines and free turbines in the structure of aircraft engines. The gas turbine rotates by gas expansion, and the free turbine rotates the turbine blades by gas blowing. There is no shaft connection between them, corresponding to the gas turbine speed and the free turbine speed respectively. The engine controller generally works in a closed loop, that is, the constant rotation mode of the free turbine speed. Under normal circumstances, the speed is stable, and the power output of the engine and the added load (such as the generator + DC load in hybrid power) should be balanced. Under a certain working condition: the engine is in the maximum power state, the speed is stable, and suddenly for some reason, the load suddenly disappears. At this time, the engine output power is still in the maximum power state, and its load torque is 0, P=T×N / 9550, the free turbine speed N must rush up, exceeding the centrifugal force of the blades, and the blades will be thrown out in a very short time. Of course, the engine controller will definitely automatically reduce the fuel supply, but it will be of no avail, because the oil reduction adjustment takes time, and the blades have been damaged at this time. The main factors leading to this situation are: component damage of the rectifier and DC load equipment, system loss of control and operational errors, which cause abnormal load shedding. The specific electrical manifestations are: the rectifier output voltage and current are abnormally 0, and the DC load voltage and current are 0.

[0052] To this end, the present embodiment provides the fast switching device, including a fast switching unit, a measuring unit, and a controller. In the turbine power generation system, protecting the engine from damage is of paramount importance. The fast switching emergency protection system is used when the DC load is suddenly abnormally unloaded when the engine is in a large state, the engine speed will rise, and the centrifugal force of the blades exceeds the limit. The essence of the fast switching emergency protection system is disturbance-free switching, which maintains the power balance relationship between the engine output power and the load. Even if the DC load is abnormal, the engine will not feel the abnormality to avoid overspeed. The fast switching device can realize millisecond switching, data transmission and other functions, and ultimately prevent the turbine blades from breaking and flying out.

[0053] To sum up, the present embodiment performs fault judgment on the system based on the measurement data collected by the measurement unit and issues a switching instruction to the fast switching unit accordingly when a fault occurs. The fast switching unit quickly disconnects the DC load system and switches the DC load system to the emergency protection load system according to the switching instruction issued by the controller. When the DC load is suddenly abnormally unloaded when the engine is in a large state, it can avoid the abnormal increase in engine speed causing the centrifugal force of the blades to exceed the limit, thereby realizing overspeed protection for the engine hybrid system test, so as to avoid the occurrence of test accidents such as turbine blades breaking and flying out.

[0054] Preferably, the fast switching unit includes a switching switch, and the switching switch includes an IGPT switching normally open switch and an IGPT switching normally closed switch, and the IGPT switching normally open switch and the IGPT switching normally closed switch are respectively connected to the emergency protection load system and the rectifier to form an interlocking relationship.

[0055] The fast switching unit of this embodiment adopts IGPT as the switching switch, which has a simple structure and is easy to control, thereby ensuring that the action time of the fast switching unit reaches the nanosecond level when performing load switching, so as to avoid the test accident of the turbine blade breaking and flying out. Moreover, since the IGPT switching normally open switch and the IGPT switching normally closed switch are respectively connected to the emergency protection load system and the rectifier and form an interlocking relationship, it also avoids the erroneous switching of the DC load system and the emergency protection load system, thereby ensuring the reliability and safety of the load switching.

[0056] Preferably, the fast switching unit includes a switching switch, and the switching switch includes a normally open high-power solid-state relay and a normally closed high-power solid-state relay. The normally open high-power solid-state relay and the normally closed high-power solid-state relay are respectively connected to the emergency protection load system and the rectifier to form an interlocking relationship.

[0057] The fast switching unit of this embodiment uses a high-power solid-state relay as a switching switch, which has the advantages of high reliability, long life, high sensitivity, low control power, good electromagnetic compatibility, fast conversion, low electromagnetic interference, etc. This ensures that the action time of the fast switching unit during load switching reaches the nanosecond level to avoid the test accident of turbine blades breaking and flying out. Moreover, since the normally open high-power solid-state relay and the normally closed high-power solid-state relay are respectively connected to the emergency protection load system and the rectifier and form an interlocking relationship, the erroneous switching of the DC load system and the emergency protection load system is also avoided, ensuring the reliability and safety of load switching.

[0058] Preferably, the emergency protection load system has the same load size as the DC load system. The benefit and purpose is to ensure that the turbine blade speed remains the same as before the load switching after the load switching when the load is off.

[0059] Preferably, the emergency protection load system includes: air-cooled AC load, air-cooled DC load with rectifier, air-cooled AC load, air-cooled DC load with rectifier, water-cooled AC load, water-cooled DC load with rectifier, electric dynamometer, eddy current dynamometer, and grid-connected load.

[0060] Preferably, the method of judging a fault of the system according to the measurement data collected by the measurement unit and issuing a switching instruction to the fast switching unit accordingly when a fault occurs specifically comprises the steps of:

[0061] Acquire measurement data collected by the measurement unit, including gas turbine speed, free turbine speed, AC voltage, and AC current;

[0062] When the engine is in a set power state above the air idle, if a fault is detected, a switching instruction is immediately sent to the fast switching unit for protection. The set power state is specifically a state of more than 80% of the full power of the engine.

[0063] Preferably, when the engine is in a set power state above the air idle, if a fault is detected, a switching instruction is immediately sent to the fast switching unit for protection, specifically including the steps of:

[0064] Engine status judgment:

[0065] When the gas turbine speed ≥ A, the free turbine speed = B, the AC voltage ≥ C, and the AC current ≥ G, the engine is judged to be in a set power state above the air idle, where A is the minimum set value of the gas turbine speed; B is the set value of the free turbine speed; C is the minimum set value of the generator output AC voltage; and G is the minimum set value of the generator output AC current;

[0066] Fault diagnosis:

[0067] If the DC current is ≤H, or the DC voltage is ≤J, or a rectifier fault digital signal is received, or a DC load system fault digital signal is received, it is considered to be a fault, where H is the minimum setting value of the DC current and J is the minimum setting value of the DC voltage;

[0068] Command sending:

[0069] Immediately send a switching command to the fast switching unit for protection.

[0070] Preferably, the electrical control system uses PLC as the central processor, adopts a distributed I / O architecture, uses the PROFINET protocol for data exchange, and realizes control instruction input and output and data acquisition functions through DI, DO, AI, and AO communication modules.

[0071] In this embodiment, the gas control system uses PLC as the central processor, adopts a distributed I / O architecture, uses the PROFINET protocol for data exchange, and realizes control instruction input and output and data acquisition functions through DI, DO, AI, and AO communication modules, ensuring reliable signal function control, fast data exchange, controllable test risks, and a robust system.

[0072] Preferably, the operating system includes a button indicator light, an emergency stop button, a warning light, a host computer, and a throttle lever. The emergency stop button and warning light are used for emergency stop and sound and light alarm, respectively; the throttle lever is used to give the loading power of the DC load system and send an RVDT signal to the EEC at the same time, forming a control mode of the throttle lever linkage load and the engine; the host computer is used to centrally remotely monitor the operating status, real-time data, alarm status and operating instructions of each subsystem transmitted to the electrical control system.

[0073] The control system of this embodiment includes a button indicator light, an emergency stop button, a warning light, a host computer, and a throttle lever. It can not only set the loading power of the DC load system, but also send an RVDT signal to the EEC to form a control method for the throttle lever to link the load and the engine. It can also monitor the working status of each system in real time and take timely action if there is a fault or alarm. It is also equipped with an emergency stop button and sound and light alarm functions to maximize the controllable risk of the test.

[0074] In summary, the aircraft engine hybrid test control system of the aforementioned embodiment of the present application adopts PLC centralized control, uses distributed I / O and Ethernet to integrate the entire system, and designs a fast switching system to solve the risk of flying cars during the test process, and finally forms a robust system with reliable signal function control, high-speed data exchange, and controllable test risks, which specifically includes:

[0075] 1. Reliable signal control:

[0076] The electrical control system, DC load system, and emergency protection load system (such as AC load) are all controlled by the mature PLC1500 series PLC, and the fast switching device uses NI controller and IGPT switching device.

[0077] 2. High-speed data exchange:

[0078] The entire system mainly uses Ethernet communication and performs fast exchange through PROFINET protocol.

[0079] 3. Experimental risks are controllable:

[0080] (1) The rapid switching system is mainly used from the perspective of test risk to prevent runaway.

[0081] (2) Overall consideration is given to the engine, generator rectifier, DC load system, fast switching device and other fault alarms, which are centrally and remotely displayed on the interface of the electrical control system, and the working status of each system is monitored in real time. If there is a fault or alarm, it is handled in time. At the same time, it is equipped with an emergency stop button and sound and light alarm functions to maximize the controllability of the test risk.

[0082] In order to further realize that the switching time of the fast switching unit does not exceed 5 ms, the preferred embodiment of the present invention will also be optimized from two aspects of software and hardware.

[0083] Software Design

[0084] The software system adopts a hierarchical approach, dividing the program into independent layers according to function and type. The high-level design completes its functions by calling the functions of the low-level, and the low-level also provides services for the higher-level layers. The system software adopts a unified software hierarchical architecture design, dividing the system into user interface layer, data management layer, interface management layer and device driver layer, such as Figure 3 shown.

[0085] The details are as follows:

[0086] Device driver layer: As a bridge between system hardware and software, the driver layer provides drivers for various bus interface devices and signal interface devices to realize functions such as sending, receiving, and event mode (callback function) receiving;

[0087] Interface management layer: The interface layer mainly manages the Ethernet interface and device signal interface, providing channels for data transmission and command interaction;

[0088] Data management layer: The data management layer mainly completes the tasks of system data generation, data reception and processing, and data storage, and provides a unified encapsulation interface for upper-layer data query and display;

[0089] User interface layer: The user interface layer mainly completes the design of the human-computer interaction interface of the system software. It adopts a graphical human-computer interaction function and can manage the tester to realize visual operation functions such as system data configuration, data query display and data output, which is easy for personnel to view and operate.

[0090] The above-mentioned layered design architecture lays the foundation for further software design and development. The layered design can improve efficiency, make system software debugging and error correction easier, and thus improve the usability and stability of the software.

[0091] The software functions mainly include data configuration, AI acquisition, DIO acquisition and control, and TCPIP communication, as follows:

[0092] Data configuration mainly realizes receiving relevant configuration parameters issued by the monitoring system and completing the coefficient configuration required by the formula.

[0093] AI collection mainly implements relevant data collection and monitoring functions after receiving the monitoring system software startup command.

[0094] DIO acquisition and control mainly realizes automatic switching of main and auxiliary channels after receiving the start command of the monitoring system software and monitoring reaches the threshold. The digital IO card has a total of 8 channel signals, DIO0-DIO3 need to be configured as output, among which:

[0095] DIO0 is the main output control (the host computer sends configuration instructions to the cRIO through the network port communication to make it change to high level);

[0096] DIO1 is the auxiliary output control (mutually exclusive with the main output control, and performs logical judgment on the first 14 test data;

[0097] DIO3 is the program running indicator light. When the host computer sends a run command to inform the cRIO underlying software to make its DIO3 high level, when the host computer sends a stop command, it controls DIO0-DIO3 to a low level.

[0098] TCP / IP communication mainly implements communication of custom protocols, as shown in Table 1.

[0099] Table 1 TCPIP custom communication protocol

[0100] ;

[0101] Hardware Design

[0102] The system uses a CRIO controller, including 1 data acquisition card and 1 digital IO card. The specific parameters are as follows:

[0103] 30 GHz dual-core CPU;

[0104] 2GB DRAM;

[0105] 4GB storage capacity;

[0106] Kintex-7 160T FPGA;

[0107] 4-slot CompactRIO controller.

[0108] NI-9202 synchronous acquisition card, 16 differential input channels with synchronous sampling, ±10 V input range, 10 kS / s / ch, 24 bits;

[0109] The NI-9401 digital IO card is available in three configurations: eight digital inputs, eight digital outputs, or four digital inputs and four digital outputs.

[0110] The signal real-time conditioning unit designed by the system has the following specific parameters:

[0111] DC voltage adjustment range: 0~2000V;

[0112] DC voltage conditioning circuit number: 1;

[0113] DC current adjustment range: 0~2000A;

[0114] Number of DC current conditioning circuits: 1;

[0115] AC voltage adjustment range: 0~1000V;

[0116] Number of AC voltage conditioning circuits: 4 circuits, real-time monitoring of the A-phase and D-phase voltages in the main circuit and the A-phase and D-phase voltages in the auxiliary circuit;

[0117] AC current adjustment range: 0~1000A;

[0118] Number of AC current conditioning circuits: 4 circuits, real-time monitoring of the A-phase and D-phase currents in the main circuit and the A-phase and D-phase currents in the auxiliary circuit;

[0119] Real-time collection of heat sink temperatures of main circuits 1-1 and 1-2;

[0120] Real-time collection of the heat sink temperature of auxiliary circuits 1-1 and 1-2;

[0121] Main circuit, auxiliary circuit, over-temperature and operation status indication;

[0122] Provides the necessary 5V and 24V power supply for the real-time switching unit IGBT control circuit.

[0123] The fast switching unit design includes demand design, IGPT selection and heat dissipation design, IGPT drive design and IGBT absorption design.

[0124] Demand Design

[0125] The generator outputs 2 three-phase electricity, a total of 6 phases, with a maximum voltage output of 705V, a maximum power of 1MW, and a single-phase current of 492A. The generator output is an AC signal. In summary, the Infineon IGBT module FF600R12KE4_E is selected as the control switch. A single IGBT has a withstand voltage of 1200V and a current of 600A. Considering the heat dissipation effect, 2 IGBT modules are selected for each phase switch in parallel. In this way, each set of switches requires 12 IGBT modules, and the two sets of switches require a total of 24 IGBT modules (main circuit and auxiliary circuit).

[0126] IGBT selection and heat dissipation design

[0127] IGBT is a power device with its own voltage drop. When the current is too large, a lot of heat will be generated. Therefore, the IGBT module needs to be cooled by an aluminum heat sink. The IGBT module is fixed on the aluminum heat sink. In order to effectively diffuse the heat and increase the contact reliability, thermal grease is applied on the contact surface between the IGBT module and the heat sink, and then the fan is used for air cooling. Each input and output is led to the input and output port through a cable.

[0128] Because there are many IGBTs and the current is large, the main circuit and the auxiliary circuit are each divided into two parts. Each part is switched by a three-phase switch. In this way, each part consists of 6 IGBTs and 1 heat sink. A total of 24 IGBTs are fixed on 4 heat sinks.

[0129] IGBT driver design

[0130] Considering the convenience of layout and wiring, 6 IGBT drivers are made into 1 control board, which is equivalent to 1 driver controller board for each three-phase switch. The IGBT driver is implemented by Infineon's recommended solution 1EDI40I12AF. 1EDI40I12AF is a single-channel isolated IGBT driver solution that can achieve a 4A current drive capability and an input-to-output isolation voltage of 1200V. Because each IGBT module has 2 IGBT tubes, the drive of each IGBT module is implemented by two 1EDI40I12AFs. The IGBT drive voltage is ±15V. Due to the large current of high-power IGBT drive and the design considering reliability and stability, the VRA2415LD-20WR3 power module of Golden Sun is selected. The VRA2415LD-20WR3 power module can achieve 24V power input and ±15V power output.

[0131] IGBT absorption design

[0132] The switching frequency of the fast switching emergency protection system is low, and the IGBT is flowing through an AC signal. Therefore, the capacitor + varistor method is used to absorb the IGBT module, reduce the impact voltage during the switching process of the IGBT module, and protect the IGBT module. The capacitor uses Rongpu's IGBT-specific non-inductive capacitor, which has high stability, flame-retardant PBT plastic shell, and epoxy resin potting with good sealing. The specification parameters are 2.5uF and 1200VDC voltage. The varistor uses 25D471KJ, and each IGBT module has two in series, which can protect the voltage to 940V. The technical parameters of IGBT absorption varistor are shown in Table 2:

[0133] Table 2

[0134] ;

[0135] In summary, the hybrid test electrical control system of the present application is designed from a systematic perspective, which can avoid independent design defects, achieve the reliability of hybrid test control, and greatly reduce possible test safety risks.

[0136] The parts not described in detail in this application are all known technologies to those skilled in the art. Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application and are not limiting. Although this application is described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of this application can be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions of this application, which should be included in the scope of the claims of this application.

Claims

1. An aircraft engine hybrid power test control system, characterized in that: include: A fast switching device is respectively connected to the engine, the generator, the rectifier, the DC load system, and the emergency protection load system circuit, and is used to quickly disconnect the DC load system and switch the DC load system to the emergency protection load system when it is detected that the hybrid power system is in a large state and a DC load loss fault occurs; An emergency protection load system is connected to the fast switching device circuit and is used to provide an emergency protection load when the hybrid power system is in a large state and a DC load loss failure occurs, so as to avoid the engine overspeed during the test causing the turbine blade to break; The first test system and the second test system are respectively used for collecting and storing the state parameters of the engine and the state data of the generator, rectifier and various load systems, and transmitting them to the electrical control system; A filter, which is arranged in a loop between the rectifier and the DC load system and is used to suppress electromagnetic interference; The control system is connected to the EEC and electrical control system circuits of the engine respectively, and is used to send the control instructions during the test to the electrical control system and EEC, and to centrally monitor the operation status, real-time data, alarm status and control instructions of each subsystem transmitted to the electrical control system through the host computer; The electrical control system is connected to the EEC, the control system, the auxiliary equipment, the fast switching device, the emergency protection load system, the DC load system, and the generator circuit respectively, and is used to realize the power supply and control of the EEC, the monitoring of the generator, the power supply and control of each load, and the power supply and monitoring of the auxiliary equipment according to the control instructions sent by the control system; The PROFINET system network uses the PROFINET protocol for fast data exchange, which is used to realize real-time and fast data exchange between the operating system and the electrical control system, as well as data communication between the electrical control system and the fast switching device, DC load system, emergency protection load system, first test system and second test system, and auxiliary equipment.

2. The aircraft engine hybrid power test control system according to claim 1, characterized in that: The fast switching device comprises: The fast switching unit is respectively connected to the generator, the rectifier and the emergency protection load system circuit, and is used to quickly disconnect the DC load system and switch the DC load system to the emergency protection load system according to the switching instruction issued by the controller; The measuring unit is respectively connected with the engine, the generator, the rectifier, and the DC load system circuit, and is used to measure the engine gas turbine speed, the free turbine speed, the AC voltage and current, the DC voltage and current, the rectifier fault digital signal, and the DC load system fault digital signal; The controller is connected to the fast switching unit, the measuring unit and the monitoring system circuit respectively, and is used to make fault judgment according to the measurement data collected by the measuring unit and send a switching instruction to the fast switching unit accordingly when a fault occurs.

3. The aircraft engine hybrid power test control system according to claim 2, characterized in that: The fast switching unit includes a switching switch, and the switching switch includes an IGPT switching normally open switch and an IGPT switching normally closed switch. The IGPT switching normally open switch and the IGPT switching normally closed switch are respectively connected to the emergency protection load system and the rectifier to form an interlocking relationship.

4. The aircraft engine hybrid power test control system according to claim 2, characterized in that: The fast switching unit includes a switching switch, which includes a normally open high-power solid-state relay and a normally closed high-power solid-state relay. The normally open high-power solid-state relay and the normally closed high-power solid-state relay are respectively connected to the emergency protection load system and the rectifier to form an interlocking relationship.

5. The aircraft engine hybrid power test control system according to claim 1, characterized in that: The load size of the emergency protection load system is consistent with that of the DC load system.

6. The aircraft engine hybrid power test control system according to claim 1, characterized in that: The emergency protection load system includes: air-cooled AC load, air-cooled DC load with rectifier, air-cooled AC load, air-cooled DC load with rectifier, water-cooled AC load, water-cooled DC load with rectifier, electric dynamometer, eddy current dynamometer, and grid-connected load.

7. The aircraft engine hybrid power test control system according to claim 2, characterized in that: The method of judging a fault of the system according to the measurement data collected by the measurement unit and sending a switching instruction to the fast switching unit accordingly when a fault occurs specifically includes the following steps: Acquire measurement data collected by the measurement unit, including gas turbine speed, free turbine speed, AC voltage, and AC current; When the engine is in a set power state above the air idle, if a fault is detected, a switching instruction is immediately sent to the fast switching unit for protection. The set power state is specifically a state of more than 80% of the full power of the engine.

8. The aircraft engine hybrid power test control system according to claim 7, characterized in that: When the engine is in a set power state above the air idle, if a fault is detected, a switching command is immediately sent to the fast switching unit for protection, which specifically includes the following steps: Engine status judgment: When the gas turbine speed ≥ A, free turbine speed = B, AC voltage ≥ C, AC current ≥ G, the engine is judged to be in a set power state above the air idle, where A is the minimum set value of the gas turbine speed; B is the set value of the free turbine speed; C is the minimum set value of the generator output AC voltage; G is the minimum set value of the generator output AC current; Fault judgment: If the DC current ≤ H, or the DC voltage ≤ J, or a rectifier fault digital signal is received, or a DC load system fault digital signal is received, it is considered to be a fault, where H is the minimum setting value of the DC current, and J is the minimum setting value of the DC voltage; Send command: immediately send a switching command to the fast switching unit for protection.

9. The aircraft engine hybrid power test control system according to claim 1, characterized in that: The electrical control system adopts PLC as the central processor, adopts a distributed I / O architecture, uses the PROFINET protocol for data exchange, and realizes control instruction input and output and data acquisition functions through DI, DO, AI, and AO communication modules.

10. The aircraft engine hybrid power test control system according to claim 1, characterized in that: The control system includes a button indicator light, an emergency stop button, a warning light, a host computer, and a throttle lever. The emergency stop button and the warning light are used for emergency stop and sound and light alarm respectively; the throttle lever is used to set the loading power of the DC load system and send an RVDT signal to the EEC at the same time, forming a control mode of the throttle lever linkage load and the engine; the host computer is used to centrally remotely monitor the operating status, real-time data, alarm status and operating instructions of each subsystem transmitted to the electrical control system.

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