Calibration device for resolver angle signal of electronic controller of aero-engine

Abstract

The invention discloses a calibration device for a resolver angle signal of an electronic controller of an aero-engine, and relates to the technical field of controllers. According to the invention, high-precision angle signal simulation is realized by adopting the resolver angle signal simulation unit and the signal acquisition unit, and the problem that the resolver angle acquisition precision of the electronic controller cannot be quickly verified can be solved without resources of a real resolver angle sensor and a part test bed; the fault injection unit is adopted to realize injection of hard faults such as open circuit, short circuit and interference and injection of soft faults such as extreme value faults and slope faults, and fault processing logic verification of angle acquisition of the rotary transformer of the electronic controller is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of controllers, and in particular relates to a calibration device for a resolver angle signal of an aero-engine electronic controller. Background Art

[0002] The accuracy and stability of the resolver angle signal acquisition of aircraft engine electronic controllers need to be experimentally verified at the control system level.

[0003] In the current engine CNC system various pump adjustment component tests, real installed electronic controllers or simulated electronic controllers are mainly used to realize the component's resolver angle signal acquisition. Since the resolver angle acquisition circuit is designed by each manufacturer, the acquisition accuracy and stability are uneven. When the resolver angle acquisition accuracy needs to be calibrated and confirmed, it can only be tested on the product component test bench using a real resolver angle sensor. It is necessary to destroy the cable between the product and the controller and use a high-precision multimeter to measure the actual angle signal. Figure 1 In addition, the existing calibration equipment can only calibrate the three integer angles of 0 / 90 / 270°, and cannot calibrate any angle. There are problems such as the inability to accurately set and calibrate the angle, the cumbersome operation process, and the waste of test resources. The current method of manually reading and recording data is inefficient and has operational errors.

[0004] With the increasing demand for in-depth verification of aircraft engine CNC systems, higher requirements are placed on the judgment logic and processing capabilities of electronic controller faults. However, the current component test bench does not have the ability to simulate resolver angle signal faults, and the verification capability is lacking. Therefore, it is necessary to develop a resolver angle signal calibration tool to perform detection through a fast and intuitive method. It is necessary to verify the values ​​within the measured angle range to improve the verification capability of aircraft engine CNC systems before leaving the factory. Summary of the invention

[0005] Based on the above background, in order to meet the development needs of the above-mentioned aircraft engine electronic controller resolver angle signal calibration method, a aircraft engine electronic controller resolver angle signal calibration tool is designed to achieve accurate simulation of resolver angle signals and injection of multiple types of faults. It can quickly complete the electronic controller resolver angle acquisition accuracy verification and fault handling logic verification without consuming component test bench resources and without using real resolver sensors, thereby improving the comprehensive verification capability of aircraft engine numerical control systems.

[0006] In view of this, according to one aspect of an embodiment of the present invention, a calibration device for a resolver angle signal of an aircraft engine electronic controller is provided, comprising a calibration analysis unit 1, a signal simulation unit 2, a fault injection unit 3, a signal acquisition unit 4 and a power supply module 5; wherein the calibration analysis unit 1 is used as a human-machine interface for running a calibration analysis software, and the calibration analysis unit 1 communicates with the signal simulation unit 2, the fault input unit 3, the signal acquisition unit 4 and the controller to be calibrated using Ethernet; the calibration analysis unit 1 is used to obtain an output angle θ1 from the signal acquisition unit 4, and an acquisition angle θ2 obtained from the controller to be calibrated. The angle is θ2; the signal simulation unit 2 is used to receive the angle command θ from the calibration and analysis unit 1 and the excitation signal of the controller to be calibrated, and convert it into a sine signal and a cosine signal with the same frequency as the excitation signal for collection by the controller to be calibrated; the fault injection unit 3 is used to receive the fault injection command from the calibration and analysis unit 1, and is connected in series between the signal simulation unit 2 and the controller to be calibrated; the signal acquisition unit 4 is used to complete the collection of the sine signal and the cosine signal output by the signal simulation unit 2, and convert them into an angle θ1, and send them to the calibration and analysis unit 1 for error calculation; the power supply module 5 is used to receive an external DC power supply, and then power the device after conversion.

[0007] Optionally, the calibration and analysis unit 1 is a Getac T800 series ruggedized tablet computer.

[0008] Optionally, the range of the angle command θ is 0-360°.

[0009] Optionally, the signal simulation unit 2 uses an STM32 microcontroller unit to calculate a given angle, and controls the DAC80508 chip to output two DC signals Vgs and Vgc through an SPI interface, wherein Vgs=sinθ, Vgc=cosθ.

[0010] Optionally, two DC given signals are respectively multiplied with the excitation signal EXC to output a sine signal sin and a cosine signal cos to be collected by the controller to be calibrated, wherein Sin=EXC*Vgs, Cos=EXC*Vgc.

[0011] Optionally, the fault injection unit 3 and the signal simulation unit 2 share the same STM32 microcontroller unit, and communicate with the calibration and analysis unit 1 via Ethernet.

[0012] Optionally, the fault injection unit 3 implements short circuit fault, signal line fault, power supply short circuit fault, ground short circuit fault and impedance injection fault by connecting relays TX2-5 in series and in parallel in the signal link.

[0013] Optionally, the signal acquisition unit 4 uses two effective value chips AD637 to complete the acquisition of the sine signal sin and the cosine signal cos respectively, and the acquired angle signal is θ1=arctan(sin / cos).

[0014] The advantages of the present invention are that a resolver angle signal simulation unit and a signal acquisition unit are used to achieve high-precision angle signal simulation, and the resources of a real resolver angle sensor and a component test bench are not required, so that the problem of being unable to quickly verify the accuracy of the resolver angle acquisition of an electronic controller can be solved. The system can calibrate a specified angle according to the requirements of different aero-engine products, and can also realize the verification and measurement of any rotation angle, with an accuracy better than ±0.1°. The test and calibration system has a self-calibration function, and can realize the functions of angle setting, measurement, feedback and angle closed-loop verification.

[0015] The fault injection unit is used to realize the injection of hard faults such as open circuit, short circuit, interference and soft faults such as polarity fault and slope fault of the resolver angle sensor, realize the fault processing logic verification function of the electronic controller resolver angle acquisition, and improve the testing and fault tolerance capabilities of the electronic controller. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a schematic diagram of the calibration of the resolver angle signal of the electronic controller in the prior art.

[0017] Figure 2 The present invention is a schematic diagram of the calibration of a resolver angle signal of an aero-engine electronic controller.

[0018] Among them, 1-calibration and analysis unit, 2-signal simulation unit, 3-fault injection unit, 4-signal acquisition unit and 5-power supply module. DETAILED DESCRIPTION

[0019] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0020] According to one aspect of an embodiment of the present invention, a calibration device for a resolver angle signal of an aircraft engine electronic controller is provided, comprising a calibration analysis unit 1, a signal simulation unit 2, a fault injection unit 3, a signal acquisition unit 4 and a power supply module 5; wherein the calibration analysis unit 1 is used as a human-machine interface for running a calibration analysis software, and the calibration analysis unit 1 communicates with the signal simulation unit 2, the fault input unit 3, the signal acquisition unit 4 and the controller to be calibrated using Ethernet; the calibration analysis unit 1 is used to obtain an output angle θ1 from the signal acquisition unit 4, and an acquisition angle θ2 from the controller to be calibrated. 2; the signal simulation unit 2 is used to receive the angle command θ from the calibration and analysis unit 1 and the excitation signal of the controller to be calibrated, and convert it into a sine signal and a cosine signal with the same frequency as the excitation signal for collection by the controller to be calibrated; the fault injection unit 3 is used to receive the fault injection command from the calibration and analysis unit 1, and is connected in series between the signal simulation unit 2 and the controller to be calibrated; the signal acquisition unit 4 is used to complete the collection of the sine signal and the cosine signal output by the signal simulation unit 2, and convert them into an angle θ1, and send them to the calibration and analysis unit 1 for error calculation; the power supply module 5 is used to receive an external DC power supply, and then power the device after conversion.

[0021] Furthermore, the calibration and analysis unit 1 is a Getac T800 series ruggedized tablet computer.

[0022] Furthermore, the range of the angle command θ is 0-360°.

[0023] Furthermore, the signal simulation unit 2 uses an STM32 microcontroller unit to calculate a given angle, and controls the DAC80508 chip to output two DC signals Vgs and Vgc through an SPI interface, wherein Vgs=sinθ, Vgc=cosθ.

[0024] Furthermore, the two DC given signals are respectively multiplied with the excitation signal EXC to output a sine signal sin and a cosine signal cos to be collected by the controller to be calibrated, wherein Sin=EXC*Vgs, Cos=EXC*Vgc.

[0025] Furthermore, the fault injection unit 3 and the signal simulation unit 2 share the same STM32 microcontroller unit, and communicate with the calibration and analysis unit 1 via Ethernet.

[0026] Furthermore, the fault injection unit 3 implements short circuit fault, signal line fault, power supply short circuit fault, ground short circuit fault and impedance injection fault by connecting relays TX2-5 in series and in parallel in the signal link.

[0027] Furthermore, the signal acquisition unit 4 uses two effective value chips AD637 to respectively complete the acquisition of the sine signal sin and the cosine signal cos, and the acquired angle signal is θ1=arctan(sin / cos).

[0028] Example 1

[0029] A method for calibrating the resolver angle signal of an aircraft engine electronic controller is implemented by a self-invented calibration tool, such as Figure 2 As shown, it includes a calibration and analysis unit 1, a signal simulation unit 2, a fault injection unit 3, a signal acquisition unit 4 and a power supply module 5.

[0030] Calibration and analysis unit 1: Use Getac T800 series rugged tablet computer as human-machine interface to run calibration and analysis software. Ethernet is used for communication between calibration and analysis unit 1 and signal simulation unit 2, fault input unit 3, signal acquisition unit 4 and controller to be calibrated. The calibration and analysis software is designed based on the VS platform and has functions such as user management, UDP communication, given angle display, recovery angle display, controller angle acquisition display, error display, curve display, and data saving. It can load the automatic test script set by the user to complete the automatic setting of the test sequence. In the test sequence, the test step execution time, angle given value, fault injection type, error judgment criteria, etc. can be set, and the test results can be automatically analyzed and uploaded to the TDM system. The calibration analysis report can be automatically generated with one click. Among them, the output angle obtained from the signal acquisition unit 4 is angle θ1, and the acquisition angle obtained from the controller to be calibrated is θ2, then the angle error is:

[0031] θe=θ2-θ1

[0032] Signal simulation unit 2: Receives the angle command θ (0-360°) from calibration analysis unit 1 and the excitation signal of the controller to be calibrated, and converts it into a sine signal and a cosine signal with the same frequency as the excitation signal for collection by the controller to be calibrated. The signal simulation unit uses an STM32 microcontroller unit to calculate the given angle and controls the DAC80508 chip to output two DC signals Vgs and Vgc through the SPI interface.

[0033] Among them, Vgs=sinθ; Vgc=cosθ

[0034] The two DC given signals are multiplied with the excitation signal EXC respectively to output the sine signal sin and the cosine signal cos to be collected by the controller to be calibrated.

[0035] Sin=EXC*Vgs

[0036] Cos=EXC*Vgc

[0037] Fault injection unit 3: Receives fault injection instructions from calibration analysis unit 1, and is connected in series between signal simulation unit 2 and the controller to be calibrated. Fault injection unit 3 and signal simulation unit 2 share the same STM32 microcontroller unit, and communicate with calibration analysis unit 1 through Ethernet. It can realize short circuit fault, signal line fault, power supply short circuit fault, ground short circuit fault, and impedance injection fault by connecting relay TX2-5 in series and parallel in the signal link. It can also increase the bias amount in Vgs and Vgc signals to realize soft fault injection such as extreme value fault and slope fault.

[0038] Signal acquisition unit 4: completes the acquisition of the sine signal sin and cosine signal cos output by the signal simulation unit 2, converts it into angle θ1, and sends it to the calibration analysis unit 1 for error calculation. The signal acquisition unit 4 shares the same STM32 microcontroller unit with the signal simulation unit 2, and communicates with the calibration analysis unit 1 through Ethernet. The signal acquisition unit 4 uses two effective value chips AD637 to complete the acquisition of the sine signal sin and cosine signal cos respectively, and the collected angle signal is:

[0039] θ1=arctan(sin / cos)

[0040] Power module 5: By receiving external DC power, after circuit design, isolation and conversion, it outputs different DC working voltages required by the above four units. The power module used in the present invention selects 24VDC power supply.

[0041] The resolver angle signal simulation unit 2 and the signal acquisition unit 4 realize high-precision angle signal simulation, solving the problem of being unable to quickly verify the accuracy of any resolver angle acquisition of the electronic controller, facilitating engineering applications, and realizing the angle correction function to solve the slight differences in the acquisition angles between electronic controllers. The fault injection unit 3 realizes the injection of hard faults such as open circuit, short circuit, interference, and soft faults such as extreme value faults and slope faults, improving the fault handling logic verification of the resolver angle acquisition of the electronic controller.

[0042] Example 2

[0043] Taking the output angle obtained by the signal acquisition unit 4 as an example, the angle symbol θ1=60°, if the acquisition angle θ2=59.958° obtained by the controller to be calibrated, then θe=θ2-θ1=-0.042°, indicating that the controller can meet the angle solution accuracy requirement of ±0.1°.

[0044] Taking the angle command θ=60° as an example, Vgs=sin60°=0.866025, Vgc=cosθ60°=0.5.

[0045] Taking the common excitation signal effective value of EXC=8Vrms and the transformation ratio of 0.5 as an example, sin=8*0.866025*0.5=3.464102Vrms, cos=8*0.5*0.5=2Vrms.

[0046] Taking the sine signal sin=3.4525Vrms and the cosine signal cos=1.9967Vrms actually collected by the controller as an example, θ2=arctan(3.4525 / 1.9967)*180 / π=59.958°.

[0047] The above is only a specific embodiment of the present invention, and the present invention is described in detail. The unexplained part is a conventional technology. However, the protection scope of the present invention is not limited to this. Any changes or substitutions that can be easily thought of by any technician familiar with the technical field within the technical scope disclosed by the present invention should be included in the protection scope of the present invention. The protection scope of the present invention shall be based on the protection scope of the claims.

Claims

1. A calibration device for resolver angle signals of an aero-engine electronic controller, characterized in that: The invention comprises a calibration analysis unit (1), a signal simulation unit (2), a fault injection unit (3), a signal acquisition unit (4) and a power supply module (5); wherein the calibration analysis unit (1) is used as a human-machine interface for running calibration analysis software, and the calibration analysis unit (1) communicates with the signal simulation unit (2), the fault input unit (3), the signal acquisition unit (4) and the controller to be calibrated using Ethernet; the calibration analysis unit (1) is used to obtain an output angle θ1 from the signal acquisition unit (4) and an acquisition angle θ2 from the controller to be calibrated; the signal simulation unit (2) is used to receive a signal from the calibration unit (4) and a signal acquisition unit (4) to obtain a signal acquisition angle θ2; the signal simulation unit (2) is used to receive a signal from the calibration unit (4) and a signal acquisition unit (4) to obtain a signal acquisition angle θ1; the signal simulation unit (2) is used to receive a signal from the calibration unit (4) and a signal acquisition unit (4) to obtain a signal acquisition angle θ2; the signal simulation unit (2) is used to receive a signal from the calibration unit (1) and a signal acquisition unit (4) to obtain a signal acquisition angle θ1; the signal simulation unit (2) is used to receive a signal from the calibration unit (1 ... The angle instruction θ of the calibration analysis unit (1) and the excitation signal of the controller to be calibrated are converted into a sine signal and a cosine signal with the same frequency as the excitation signal for collection by the controller to be calibrated; the fault injection unit (3) is used to receive the fault injection instruction from the calibration analysis unit (1) and is connected in series between the signal simulation unit (2) and the controller to be calibrated; the signal acquisition unit (4) is used to complete the collection of the sine signal and the cosine signal output by the signal simulation unit (2), and convert them into an angle θ1, which is sent to the calibration analysis unit (1) for error calculation; and the power supply module (5) is used to receive an external DC power supply and convert it to supply power to the device.

2. The device according to claim 1, characterized in that The calibration and analysis unit (1) is a Getac T800 series rugged tablet computer.

3. The device according to claim 1, characterized in that The range of the angle command θ is 0-360°.

4. The device according to claim 1, characterized in that The signal simulation unit (2) uses an STM32 microcontroller unit to calculate a given angle, and controls a DAC80508 chip through an SPI interface to output two DC signals Vgs and Vgc, wherein Vgs=sinθ, and Vgc=cosθ.

5. The device according to claim 4, characterized in that The two DC given signals are multiplied with the excitation signal EXC respectively to output the sine signal sin and the cosine signal cos to be collected by the controller to be calibrated, where Sin = EXC*Vgs, Cos = EXC*Vgc.

6. The device according to claim 1, characterized in that The fault injection unit (3) and the signal simulation unit (2) share the same STM32 microcontroller unit and communicate with the calibration analysis unit (1) via Ethernet.

7. The device according to claim 6, characterized in that The fault injection unit (3) realizes short circuit fault, signal line fault, power supply short circuit fault, ground short circuit fault and impedance injection fault by connecting the relay TX2-5 in series and in parallel in the signal link.

8. The device according to claim 1, characterized in that The signal acquisition unit (4) uses two effective value chips AD637 to respectively complete the acquisition of the sine signal sin and the cosine signal cos, and the acquired angle signal is θ1=arctan(sin / cos).

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