Marine engine electronic control system in-loop simulation test system

Abstract

The invention provides an in-loop simulation test system for an electric control system of a marine engine, which is used for monitoring the driving state of a high-side driving valve during the operation of the engine by simulating a rotating speed signal of the engine, calculating the opening degree of the valve through an input PWM (Pulse-Width Modulation) wave duty ratio, monitoring and outputting a plurality of groups of analog quantity signals and digital quantity signals, and realizing the in-loop simulation test of the electric control system of the marine engine. The real-time working state of the engine electric control system is simulated, and errors caused by manual intervention are solved.

Description

Technical Field

[0001] The present invention relates to the technical field, and in particular to an in-the-loop simulation test system for an electronic control system of a marine engine. Background Art

[0002] In the current development process of marine engine electronic control systems, a significant challenge is how to efficiently and economically verify its comprehensive performance under full load and full operating conditions when conducting engine tests directly at the end of development. The complexity of engine tests and the high time and economic costs make improving the success rate of tests a key technical issue that needs to be solved urgently. Hardware-in-the-loop (HIL) testing technology, with its ability to highly simulate real engine operating conditions at the hardware level, provides an innovative solution to this problem. By conducting detailed HIL tests on the electronic control system before engine tests, it can not only effectively improve the safety of engine tests and reduce additional costs caused by test failures, but also significantly reduce the economic burden of the overall R&D cycle.

[0003] However, it is worth noting that the hardware-in-the-loop test system on the market has matured in electric vehicles and their key components (such as motor controllers and battery management systems), but the specific needs of marine engine electronic control systems have not yet been fully covered. Marine engine electronic control systems require a more complex and diverse hardware-in-the-loop test solution to ensure comprehensive and accurate control, monitoring and safety protection of marine diesel engines.

[0004] Given the uniqueness and complexity of the operating environment of marine diesel engines, the design of hardware-in-the-loop test scenarios must fully consider various extreme operating conditions and changing conditions, which places higher requirements on the accuracy, flexibility and reliability of the test system. Summary of the invention

[0005] The purpose of the technical solution of the present invention is to propose a hardware-in-the-loop test system designed specifically for marine engine electronic control systems, aiming to improve the development efficiency and product quality of marine engine electronic control systems through efficient and economical testing methods.

[0006] In order to achieve the above-mentioned invention object, the technical solution of the present invention provides a marine engine electronic control system in-the-loop simulation test system, which is used to simulate the use environment of the engine electronic control system in actual work. The marine engine electronic control system in-the-loop simulation test system includes software and hardware; the software includes FPGA, Real-Time, and main system interface, and the hardware includes a test computer host computer based on NI CompactRIO controller, Ni cRIO chassis, and C series modules;

[0007] FPGA, used to obtain the requirements of the engine electronic control system, and calculate and simulate the generation of PWM wave signals of timing, crankshaft speed and camshaft speed, high-side drive signals, valve opening signals, crankshaft direction, and crankshaft camshaft missing tooth signals according to the requirements;

[0008] The high-side drive signal is configured according to the design parameters of different fuel injection valves. When the fuel injection valve current value reaches the upper limit of the set value interval, the fuel injection valve is considered to be open, and the corresponding high-side drive signal is output. When the fuel injection valve current value is less than the lower limit of the set value interval, the fuel injection valve is considered to be open, and the corresponding high-side drive signal is output and transmitted to Real-Time.

[0009] The waveform duty cycle is calculated according to the PWM wave signal, and compared to see whether it is within the preset valve opening range. If it is within the preset valve opening range, a valve opening signal is obtained;

[0010] Real-Time, used to obtain the timing, crankshaft speed and camshaft speed PWM wave signals, high-side drive signals, valve opening signals, crankshaft direction, crankshaft and camshaft missing tooth signals from the FPGA to configure the engine electronic control system;

[0011] The main system interface is used to monitor the engine control system configured according to Real-Time during the test and to simulate signals in actual external work.

[0012] Preferably, the test computer host computer is used for inputting external signals involved in the operation of the engine electronic control system and monitoring the signals to be monitored of the engine control system.

[0013] Preferably, when the Real-Time configures the current range of the engine electronic control system according to the high-side drive signal, when the state of the injection valve corresponding to the high-side drive signal is observed on the main system interface, the crankshaft angle and time, and the timing of opening and closing of the monitoring valve and the interval angle of opening and closing are provided on the main interface.

[0014] Preferably, after the Real-Time output of crankshaft speed, crankshaft direction, and crankshaft camshaft missing tooth signals is configured to configure the engine electronic control system, the change of the throttle rack position signal of the engine electronic control system is observed, and according to the relevant requirements of the engine electronic control system, the lubricating oil and fuel related signals are input to observe the valve opening signal.

[0015] Preferably, the ring simulation test system calculates the high-side drive signal according to the injection valve current value corresponding to the valve opening signal to obtain the high-side drive signal, and displays the main injection signal and micro injection signal corresponding to the high-side drive signal on the main interface.

[0016] Preferably, the ring simulation test system obtains an emergency stop signal from the engine electronic control system, and simulates an emergency oil unloading valve to cause oil and / or gas cut-off according to the emergency stop signal.

[0017] Preferably, the hardware further includes an 8-way AI signal module for receiving a throttle rack position signal sent by the engine electronic control system.

[0018] Preferably, the hardware also includes a 4-way AO signal module for outputting lubricating oil pressure signal, lubricating oil temperature signal, fuel pre-supply pump pressure signal, high-temperature water temperature signal, and control pressure signal to the engine electronic control system.

[0019] Preferably, the hardware also includes a two-in-one module of 8 DI signals and 8 DO signals, which is used to simulate and generate the crankshaft and camshaft missing tooth signal, camshaft missing tooth signal, turning machine engagement and disengagement signal, dynamometer ready signal, security stop signal, external safety signal, and emergency oil unloading valve opening and closing signal.

[0020] Preferably, the in-the-loop simulation test system is adapted to various sensors by converting current signals into physical quantity signals of corresponding ranges.

[0021] The technical solution of the present invention proposes an in-the-loop simulation test system for a marine engine electronic control system, which simulates the real-time working state of the engine electronic control system by simulating the engine speed signal, monitoring the driving state of the high-side drive valve when the engine is running, calculating the valve opening by the input PWM wave duty cycle, monitoring and outputting multiple groups of analog signals and digital signals, and solving the error caused by human intervention. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 A schematic diagram of an in-the-loop simulation test system architecture for a marine engine electronic control system provided by an embodiment of the present invention;

[0023] Figure 2 A schematic diagram of an interface of an in-the-loop simulation test system for an electronic control system of a marine engine provided by an embodiment of the present invention;

[0024] Figure 3 A start-up flow chart of an in-the-loop simulation test system for an electronic control system of a marine engine provided by an embodiment of the present invention;

[0025] Figure 4 An emergency stop flow chart of an in-the-loop simulation test system for an electronic control system of a marine engine provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0026] The present invention will be further described below in conjunction with specific embodiments. It should be understood that these embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention. In addition, it should be understood that after reading the content taught by the present invention, those skilled in the art can make various changes or modifications to the present invention, and these equivalent forms fall within the scope limited by the appended claims of the application equally.

[0027] The embodiment of the present invention provides a marine engine electronic control system in-the-loop simulation test system, the software of the whole system consists of three parts: FPGA, Real-Time, and main system interface. The hardware of the engine hardware in-the-loop test system is based on the NI CompactRIO controller, and consists of a test computer host computer, a Ni cRIO chassis, and C series modules. The host computer is used to input various external signals involved in the operation of the engine electronic control system and monitor various signals to be monitored in the engine control system.

[0028] The in-the-loop simulation test system for the electronic control system of a marine engine simulates the actual working environment of the electronic control system of the engine, outputs PWM wave signals of crankshaft and camshaft speeds, simulates high-side drive signals, valve opening signals, and some analog and digital input and output involved in the entire operation of the engine.

[0029] Timing, crankshaft speed, crankshaft direction, crankshaft camshaft missing tooth signal (programmed in FPGA according to the engine control system model and the logic requirements to be input to the engine control system) can be calculated and simulated in FPGA according to the requirements of the engine electronic control system, output on NI-9375 and connected to the engine electronic control system. In Real-Time, you can configure the speed, missing tooth position, crankshaft direction, and observe the timing. (The software part of the entire engine hardware-in-the-loop test system is composed of the underlying FPGA programming, the real-time system Real-Time and the system main interface. The real-time system calls the FPGA code and configures the relevant parameters. The system main interface is used to monitor the engine control system during the test and simulate the signals in the actual external work) This programming can first meet the high response time requirements of the engine control system (milliseconds and microseconds) and many parameters can be configured and changed at any time in RT, which increases the applicability of the simulation system. RT FIFO technology is used in RT to ensure the integrity of data in the process of large data volume and frequent data interaction. The programming language of the entire in-the-loop simulation system is G language, which is a language based on labview.

[0030] The high-side driver can set the module current range in FPGA to correspond to the opening and stopping current of the driving valve. In actual testing, according to the design parameters of different injection valves, when the current value reaches the upper limit of the set value range (there is a large current when the injection valve is opened), it is considered that the injection valve is open at this time. When it is less than the lower limit of the set value, it is considered that the injection valve is closed. The current range is configured in the Real-Time system, and then the crankshaft angle and time corresponding to the opening and closing of the injection valve are observed in the main interface. The timing of the opening and closing of the monitoring valve and the interval angle of opening and closing are provided in the main interface.

[0031] The valve opening signal needs to monitor the input high-speed PWM wave signal in real time, and calculate the valve opening according to the duty cycle (the innovation of the system lies in converting the duty cycle signal into the valve opening signal, which is extremely fast and sensitive to monitoring. In many conventional duty cycle monitoring, it is not necessary to achieve such high accuracy, but this hardware-in-the-loop simulation system can meet the monitoring requirements due to the particularity of the engine electronic control system). The corresponding function is implemented in the FPGA, and the waveform duty cycle and the corresponding valve opening range can be set (the PCV valve outputs a signal of duty cycle change, and this duty cycle signal has a certain range, which corresponds to the real-time opening of the valve). In the Real-Time system, it is configured according to the actual situation.

[0032] The analog signal current signal (4-20mA) is converted into the corresponding physical quantity signal after calculation according to the range of the measured object (the analog signal has two types: AI and AO. AI is provided by the engine control system and the in-the-loop simulation system is responsible for monitoring. AO is provided by the in-the-loop simulation system and is responsible for simulating the external signal of the engine control system. The general monitoring is 4mA corresponding to the lower limit of the physical parameter and 20mA corresponding to the upper limit of the physical parameter) (such as 0-10bar), such as pressure, temperature, etc. The calculation is completed in the FPGA, and some analog quantities that do not need to be changed are configured in the RT. The analog quantities that need to be changed frequently provide modification functions in the main interface.

[0033] System architecture Figure 1 The main interface of the marine engine electronic control system in-loop simulation test system is shown in Figure 2As shown. Before the system is running, the corresponding IO interface of the control system needs to be connected to the corresponding channel of the engine control module. In the vehicle preparation process, the in-loop test platform provides lubricating oil pressure, lubricating oil temperature, fuel pre-supply pressure, high temperature water temperature, control air pressure and can modify the above parameters. The hardware-in-the-loop test system outputs a dynamometer ready signal (the in-the-loop simulation system provides a dynamometer ready signal, and then the engine electronic control system feeds back a dynamometer start signal, which can be considered as a sign that the engine electronic control system is ready). After the dynamometer is started, the dynamometer monitoring indicator light can be observed to be on. The in-the-loop test system outputs crankshaft and camshaft signals, and the throttle rack position (which is just an AI signal from an engine electronic control system) can be observed to change. According to the requirements (these requirements are just to give these AO quantities a certain value based on different systems and then transmit it to the electronic control system), lubricating oil, fuel and other signals are input, and the valve signal (injection signal) is observed. The in-the-loop test system can receive the valve opening signal (PCV) sent by the control system, and feed back the micro-injection injection signal based on the opening information (corresponding to the high-side drive mentioned above, here it is displayed as main injection and micro-injection on the main interface). The system can send out simulated cranking machine engagement and disengagement signals: the in-loop test platform can receive emergency stop signals, and after receiving the emergency stop signal, simulate the emergency oil unloading valve opening (oil and gas cut-off) (this is just a button. When an emergency stop occurs, you can press the button after receiving the emergency stop signal feedback, and then observe the speed. The speed drops to 0, which means that the emergency oil unloading control function of the electronic control system is normal) (To verify the emergency stop function of the engine electronic control system, you can set the electronic control system to a safety stop and external safety signal in the in-loop test system. If the electronic control system functions normally, an emergency stop signal should be fed back); after the fuel of the engine model fuel system is cut off, the speed drops to 0. (In Figure 2 In the figure, the leftmost column of signals is the AO signal, which is used to simulate the external pressure and temperature signals when the electronic control system is actually working. The throttle rack position is sent by the electronic control system to the in-loop simulation system, which is used to monitor the main injection and micro injection. It is used to monitor the opening, closing and interval crankshaft angle and time of the two valves. The dynamometer start and stop signal, the lubricating oil pre-supply pump start and stop signal and the emergency stop signal are the feedback signals of the electronic control system, which are three DI signals. On the interface, the three lights are on and off. The PCV valve opening signal is the PWM duty cycle signal sent by the electronic control system mentioned above, which is calculated and converted into a valve opening signal; the rightmost is five buttons, which are used to press when needed according to the control requirements of the engine electronic control system during testing, and then observe the feedback).

[0034] The control system startup process is as follows Figure 3 As shown in the figure, the dynamometer start and stop, throttle rack position, speed, main injection signal, and micro injection signal are all provided by the hardware-in-the-loop test system (the specific process has been described in the previous paragraph). The emergency stop process of the control system is as follows Figure 4As shown, the throttle rack position, speed, main injection fuel injection signal, micro injection fuel injection signal, emergency oil unloading valve signal, and dynamometer start and stop signal are all provided by the hardware-in-the-loop test system.

[0035] The embodiments of the present invention have the following advantages:

[0036] 1. Reliable and safe: Improve the safety of marine engine electronic control systems and reduce the accident rate. The engine electronic control system in-loop simulation test system can simulate the engine speed signal, monitor the driving state of the high-side drive valve when the engine is running, calculate the valve opening through the input PWM wave duty cycle, monitor and output multiple groups of analog signals and digital signals, and simulate the real-time working state of the engine electronic control system, which is helpful to find problems early and improve system performance;

[0037] 2. Real-time performance: The hardware of the engine electronic control system in-the-loop simulation test system is based on FPGA and real-time operating system, which can provide reliable real-time performance and precise timing control. It is suitable for data acquisition and control applications that require high precision and high performance, ensuring that there will be no data loss and meeting the testing requirements of marine engine control modules;

[0038] 3. High test efficiency: The engine electronic control system in-the-loop simulation test system is efficient and reliable, while reducing manual intervention and errors;

[0039] 4. Low testing cost: The engine electronic control system in-the-loop simulation test system tests the object under test by simulating the real controller. After the hardware in the loop test system is connected to the engine electronic control system, the hardware in the loop test system configures the engine speed signal, high-side drive, valve opening monitoring signal, etc. according to the test requirements, and then interacts with the engine control system to provide an external simulation environment for the normal operation and emergency stop of the engine electronic control system, reducing the time cost and economic cost of using the real controller in subsequent tests;

[0040] 5. Comprehensive test results: Since the test scenario of the engine electronic control system in-the-loop simulation test system is virtual, it can simulate external conditions that are difficult to achieve with actual test equipment, and can easily create a more comprehensive test environment;

[0041] 6. Strong scalability: The engine electronic control system in-loop simulation test system includes NI's C series modules: one NI-9203 (8-way AI signal module) is used to receive the throttle rack position signal, main injection current and micro injection current from the engine electronic control system, two NI-9265 (4-way AO signal modules) are used to output lubricating oil pressure signal, lubricating oil temperature signal, fuel pre-supply pump pressure signal, high-temperature water temperature signal, and control pressure signal to the engine electronic control system, and one NI-9375 (8-way DI signal, 8-way DO signal two-in-one module) is used to simulate the generation of engine crankshaft missing tooth signal, camshaft missing tooth signal, cranking machine engagement and disengagement signal, dynamometer ready signal, security stop signal, external safety signal, emergency oil unloading valve opening and closing signal; collect the dynamometer start and stop signal, lubricating oil pre-supply pump start and stop signal and emergency stop signal output by the engine electronic control system. The modular design allows the system to be expanded and upgraded as needed according to actual test conditions;

[0042] 7. It can simulate the speed, angle and missing tooth signals of various crankshafts and camshafts, with a wider range of adaptation; it can adapt to various sensors and convert current signals into physical quantity signals of corresponding ranges; it can calculate the valve opening according to the input PWM wave duty cycle, and it can be configured.

Claims

1. A marine engine electronic control system in-loop simulation test system, characterized in that: Used to simulate the use environment of the engine electronic control system in actual work, the marine engine electronic control system in-loop simulation test system includes software and hardware; the software includes FPGA, Real-Time, and main system interface, and the hardware includes a test computer host computer based on NI CompactRIO controller, NicRIO chassis, and C series modules; FPGA, used to obtain the requirements of the engine electronic control system, and calculate and simulate the generation of PWM wave signals of timing, crankshaft speed and camshaft speed, high-side drive signals, valve opening signals, crankshaft direction, and crankshaft camshaft missing tooth signals according to the requirements; The high-side drive signal is configured according to the design parameters of different fuel injection valves. When the fuel injection valve current value reaches the upper limit of the set value interval, the fuel injection valve is considered to be open, and the corresponding high-side drive signal is output. When the fuel injection valve current value is less than the lower limit of the set value interval, the fuel injection valve is considered to be open, and the corresponding high-side drive signal is output and transmitted to Real-Time. The waveform duty cycle is calculated according to the PWM wave signal, and compared to see whether it is within the preset valve opening range. If it is within the preset valve opening range, a valve opening signal is obtained; Real-Time, used to obtain the timing, crankshaft speed and camshaft speed PWM wave signals, high-side drive signals, valve opening signals, crankshaft direction, crankshaft and camshaft missing tooth signals from the FPGA to configure the engine electronic control system; The main system interface is used to monitor the engine control system configured according to Real-Time during the test and to simulate signals in actual external work.

2. The in-the-loop simulation test system for the electronic control system of a marine engine according to claim 1, characterized in that: The test computer host computer is used for inputting external signals involved in the operation of the engine electronic control system and monitoring the signals to be monitored of the engine control system.

3. The in-the-loop simulation test system for the electronic control system of a marine engine according to claim 1, characterized in that: When the Real-Time configures the current range of the engine electronic control system according to the high-side drive signal, when the state of the injection valve corresponding to the high-side drive signal is observed on the main system interface, the crankshaft angle and time, and the timing of opening and closing of the monitoring valve and the interval angle of opening and closing are provided on the main interface.

4. The in-the-loop simulation test system for the electronic control system of a marine engine according to claim 1, characterized in that: After the Real-Time output of crankshaft speed, crankshaft direction, and crankshaft camshaft missing tooth signals is used to configure the engine electronic control system, the change of the throttle rack position signal of the engine electronic control system is observed, and according to the relevant requirements of the engine electronic control system, the lubricating oil and fuel related signals are input to observe the valve opening signal.

5. The in-the-loop simulation test system for the electronic control system of a marine engine as claimed in claim 4, characterized in that: The loop simulation test system calculates the high-side drive signal according to the injection valve current value corresponding to the valve opening signal to obtain the high-side drive signal, and displays the main injection signal and the micro injection signal corresponding to the high-side drive signal on the main interface.

6. The in-the-loop simulation test system for the electronic control system of a marine engine according to claim 1, characterized in that: The ring simulation test system obtains an emergency stop signal from the engine electronic control system, and simulates an emergency oil unloading valve to cause oil and / or gas cut-off according to the emergency stop signal.

7. The in-the-loop simulation test system for the electronic control system of a marine engine as claimed in claim 4, characterized in that: The hardware also includes an 8-way AI signal module for receiving a throttle rack position signal sent by the engine electronic control system.

8. The in-the-loop simulation test system for the electronic control system of a marine engine according to claim 1, characterized in that: The hardware also includes a 4-way AO signal module for outputting lubricating oil pressure signal, lubricating oil temperature signal, fuel pre-supply pump pressure signal, high-temperature water temperature signal, and control pressure signal to the engine electronic control system.

9. The in-the-loop simulation test system for the electronic control system of a marine engine according to claim 1, characterized in that: The hardware also includes an 8-way DI signal and 8-way DO signal two-in-one module, which is used to simulate and generate the crankshaft and camshaft missing tooth signal, camshaft missing tooth signal, turning machine engagement and disengagement signal, dynamometer ready signal, security stop signal, external safety signal, and emergency oil unloading valve opening and closing signal.

10. The in-the-loop simulation test system for electronic control system of a marine engine according to claim 1, characterized in that: The in-the-loop simulation test system is adapted to various sensors by converting current signals into physical quantity signals of corresponding ranges.

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