Water cooling system for main bearing test bed and control method thereof

Abstract

The invention provides a water cooling system for a main bearing test bed and a control method of the water cooling system, and belongs to the technical field of shield tunneling machine tests. Comprising a cold source, a water tank, a cold water circulating pump, a water distribution unit, a heat exchange unit and a cooling water loop, the cold source and the water tank form a cooling loop; the water tank comprises a cold water chamber and a hot water chamber, the cold water chamber is connected with an internal circulation water return pipe of the main bearing test bed and a water outlet pipe of the cold source, the hot water chamber is connected with an internal circulation water outlet pipe of the main bearing test bed and a water return pipe of the cold source, and the cold source conveys water in the hot water chamber into the cold water chamber; cooling water in the cold water tank chamber is distributed to each branch pipeline through the water distribution unit and is conveyed to each component in the heat exchange unit for heat exchange; and the water subjected to heat exchange is connected with a cooling water return port of the hot water chamber through a cooling water loop so as to be conveyed into the hot water chamber of the water tank. According to the invention, the water cooling system is additionally arranged on the existing main bearing test bed, so that the main bearing test bed can be automatically cooled in the test process.

Description

Technical Field

[0001] The invention belongs to the technical field of shield machine testing, and relates to a water cooling system for a main bearing test bench and a control method thereof. Background Art

[0002] As the heart of the tunnel boring machine, it is necessary to conduct bench tests on the main bearing to ensure its reliability. The main bearing is large in size and heavy in load, so its temperature rises quickly during bench tests. However, most electromechanical and hydraulic systems have certain requirements for operating temperature, so a cooling system needs to be built to control the operating temperature. During the test, the main factors that need to be controlled are the heating of the motor, the heating of the reducer, the heating of the ring gear transmission, the heating of the main bearing under load, and the heating of the electrical system. Considering the equipment operating conditions, heat dissipation requirements and economy, water is a more suitable cooling medium. The equipment has a large heating power and requires a large cooling water flow rate. If it cannot be cooled in time, the test equipment will be shut down or even components will be damaged. The heating power of each part is different, and the required cooling water flow rate is different. In addition, this system was built for the first time and there is no accurate heating value parameter. In order to improve heat exchange efficiency, reduce energy consumption, and accurately dissipate heat to ensure equipment operation, it is necessary to build a water cooling system that can adaptively adjust the operating state according to the heating conditions of each part of the bench.

[0003] The existing patent technology of bearing test benches does not mention the construction of water cooling system, and mainly focuses on the structure. Patents related to cooling are mainly concentrated in the fields of automobiles, computer server units, refrigeration equipment, etc., and the flow of a single channel is adjusted by setting a separate pump on each channel, which has high cost and energy consumption and low space utilization. The technology of adjusting the flow by controlling the valve opening mainly adjusts the difference between the set flow value and the actual flow value, and cannot make adaptive adjustments to the temperature. Summary of the invention

[0004] In order to solve the problems in the prior art, the present invention provides a method for constructing a water cooling system for a main bearing test bench of a tunnel boring machine and a method and device for adaptively adjusting the operating state according to the heat conditions of various parts of the test bench, so as to adapt to the different cooling water flow rates required for the different heat powers of various parts of the test bench and to adaptively adjust the cooling water demand according to the working conditions.

[0005] The present invention provides a water cooling system for a main bearing test bench, comprising a cold source, a water tank, a cold water circulation pump, a water distribution unit, a heat exchange unit and a cooling water circuit; The cold source forms a cooling circuit with the water tank through pipelines; The water tank comprises a cold water chamber and a hot water chamber which are spaced apart from each other, the cold water chamber is connected to the inner circulation water return pipe of the main bearing test bench and the water outlet pipe of the cold source, the hot water chamber is connected to the inner circulation water outlet pipe of the main bearing test bench and the water return pipe of the cold source, the cold source extracts water from the hot water chamber in the water tank, cools it and then sends it to the cold water chamber of the water tank; The cold water circulation pump is connected to the water outlet provided on the cold water chamber of the water tank, and is used to extract the cooling water in the cold water chamber and send it to the water distribution unit. After the cooling water is distributed by the water distribution unit, it is sent to various components in the heat exchange unit through various branch pipes provided on the water distribution unit for heat exchange. The water after heat exchange is connected to the cooling water return port of the hot water chamber through the cooling water loop to be transported to the hot water chamber of the water tank.

[0006] Furthermore, the water cooling system of the main bearing test bench also includes a monitoring unit; The monitoring unit includes a temperature sensor and a water flow sensor. The temperature sensor is provided in multiple pieces and arranged respectively inside the cold water chamber, inside the heat exchange unit and on the cooling water circuit before and after the heat exchange unit; the water flow sensor is provided in multiple pieces and arranged respectively on multiple branch pipes.

[0007] Optionally, the water distribution unit is connected to a plurality of branch pipes for interconnecting with the gear oil, reducer, motor and electrical system of the main bearing test bench, and a valve group is provided on each branch pipe, and the opening of each valve group is adjusted by a single electromagnetic force.

[0008] Furthermore, the water cooling system of the main bearing test bench also includes a control unit for signal connection of a cold source, multiple temperature sensors, multiple water flow sensors, a cold water circulation pump and various electromagnetic forces; the control unit includes a control circuit board and a control program that are interconnected.

[0009] The present invention also provides a control method for a water cooling system of a main bearing test bench, comprising the following steps: Step 1: assemble the water cooling system for the main bearing test bench as described above, and connect the water cooling system for the main bearing test bench with the existing main bearing test bench; Step 2: Take the recommended operating temperature range of the gear oil branch, reducer branch, motor group branch, electrical system branch and water tank of the main bearing test bench as the thermal balance target temperature of cooling; And, based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed and maximum test torque of the main bearing test bench during the test, various parameters of the water cooling system of the main bearing test bench are preset; Step 3: automatically modify the preset parameters according to the actual input parameters of the main bearing test bench during the test, and load and bind the modified parameters into the control program; Step 4: Run the water cooling system of the main bearing test bench based on the modified parameters, and adjust the temperature of each water pipe of the water distribution unit.

[0010] Optionally, the specific process of presetting various parameters of the water cooling system of the main bearing test bench is as follows: S2.1, Assume the radius of the test main bearing is , the bearing test axial load is , radial load is The overturning moment is , the bearing raceway friction coefficient is , the main bearing test speed is , the main bearing test torque is , the main bearing ring gear transmission heating coefficient is , the heat generation coefficient of the reducer transmission is , the motor transmission heating coefficient is , the heating coefficient of the electrical system is And the heat dissipation margin factor is ; Preliminary estimate of the heat generation power of the bearing under load , Bearing gear ring transmission heat power , Heat generation power of reducer transmission , Motor transmission heating power , Electrical system heating power , Rated cooling power of cold source and determining the ratio of the opening cross-sectional sizes of each branch pipe of the water distribution unit; S2.2, Assume that the specific heat capacity of cooling water is , cooling water density is , heat transfer power is , the temperature before heat exchange is And the temperature after heat exchange is , calculate the total cooling water flow of each component in the heat exchange unit ; S2.3, based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed and maximum test torque of the main bearing test bench during the test, and the temperature difference before and after heat exchange obtained in actual engineering applications of the main bearing test bench , calculate the maximum flow rate of cooling water required by each component in the heat exchange unit; Based on the minimum bearing load, minimum radial load, minimum overturning moment, minimum test speed and minimum test torque of the main bearing test bench during the test, and the temperature difference before and after heat exchange obtained in the engineering application of the main bearing test bench , calculate the minimum flow rate of cooling water required by each component of the heat exchange unit.

[0011] Optionally, the specific process of automatically modifying the preset parameters is as follows: S3.1. Calculate the actual flow required by each component of the heat exchange unit according to the actual input parameters of the main bearing test bench during the test; the actual input parameters include the actual input axial load, the actual input radial load, the actual input overturning moment, the actual input test speed and the actual output test torque; S3.2. Preset the output flow of the cold water circulation pump and the cross-sectional dimensions of each branch opening of the water distribution unit, and operate the water cooling system of the main bearing test bench based on the preset parameters; At the same time, each water flow sensor detects the actual flow data of each branch pipeline in real time and feeds it back to the control program. The control program compares the received actual flow data with the preset water flow data, and adjusts the valve group opening of each branch pipeline of the water distribution unit according to the comparison result; When all components of the heat exchange unit reach the set thermal equilibrium target temperature, the current data of each water flow sensor and the data of each temperature sensor are recorded to obtain a first set of temperature data and a first set of water flow data; S3.3, after the water cooling system of the main bearing test bench continues to operate for a period of time based on the first set of temperature data and the first set of water flow data, the data of each corresponding temperature sensor and each water flow sensor are recorded again to obtain a second set of temperature data and a second set of water flow data; S3.4, comparing the first set of temperature data with the second set of temperature data, and adjusting the flow of each branch pipeline based on the comparison result; S3.5. In the process of adjusting the output flow of each branch pipeline based on the comparison results, if the output flow of each branch pipeline has reached the maximum value and the temperature of each component of the heat exchange unit still cannot reach the thermal equilibrium target temperature, the temperature in the cold water chamber in the water tank is cooled down so that the temperature of each component of the heat exchange unit reaches the thermal equilibrium temperature and the final heating coefficients are obtained; at the same time, the current heating coefficients are loaded into the control program and bound to the corresponding operating parameters in the control program and the current heating coefficients are fixed to complete the automatic modification of the preset parameters.

[0012] Optionally, the specific process of adjusting the flow of each branch pipeline based on the comparison result is as follows: If the temperature fluctuation range is within ±3℃, no treatment will be done; If the temperature rise range exceeds +3°C, the corresponding heating coefficient is increased and the output flow of the corresponding branch pipeline is recalculated to increase the output flow of the corresponding branch pipeline; If the temperature drops beyond -3°C, the corresponding heating coefficient is reduced and the output flow of the corresponding branch pipeline is recalculated to reduce the output flow of the corresponding branch pipeline; At the same time, the cold water circulation pump and the water distribution unit synchronously adjust the output flow of the cooling circuit and the opening cross-section size of each branch according to the regulation of the output flow of the corresponding branch pipeline.

[0013] Optionally, when cooling the temperature in the cold water chamber in the water tank, a single cooling method of 1°C is used for gradual cooling, and steps S3.2 and S3.3 are repeated in the process of gradually cooling the temperature in the cold water chamber until the temperatures of all components of the heat exchange unit reach the thermal equilibrium temperature. The real-time data obtained by the current temperature sensors and water flow sensors are recorded to obtain a third set of temperature data and a third set of water flow data, that is, the final heating coefficients are obtained.

[0014] Optionally, the specific process of regulating the temperature of each water pipe of the water distribution unit is as follows: S4.1. Calculate the required flow of each branch pipe of the water distribution unit based on the actual input parameters of the main bearing test bench during the test process. Preset the opening of each branch pipe of each valve group according to the required cooling flow, and preset the displacement of the cold water circulation pump according to the sum of the required flow of each branch pipe; S4.2, the water cooling system of the main bearing test bench starts to operate continuously based on the opening of each branch pipe and the displacement of the cold water circulation pump preset in S4.1, and judges whether the temperature of each component of the heat exchange unit is stable during its continuous operation; If the temperature of each component of the heat exchange unit is equal to the preset temperature, it means that the temperature of each component of the heat exchange unit is in a stable state, that is, the water cooling system of the main bearing test bench continues to operate based on the parameters preset in S4.1; If the temperature of each component of the heat exchange unit is not equal to the preset temperature, it means that the temperature of each component of the heat exchange unit is in an unstable state, that is, the preset temperature is regulated in the following manner: If the temperature of each component of the heat exchange unit is greater than the preset temperature + 3°C, the cold water flow rate of each branch pipe of the water distribution unit is appropriately increased; If the temperature of each component of the heat exchange unit is less than or equal to the preset temperature + 3°C, continue to determine the temperature of each component; If the temperature of each component of the heat exchange unit is lower than the preset temperature of -3°C, the cold water flow rate of each branch pipe of the water distribution unit is appropriately reduced; If the temperature of each component of the heat exchange unit is greater than or equal to the preset temperature -3°C, the node returns to the preset temperature and starts continuous operation to continue operation.

[0015] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention provides a water cooling system for a main bearing test bench. By adding a water cooling system to an existing main bearing test bench, the main bearing test bench can be automatically cooled during the test. The water tank is configured to include a cold water chamber and a hot water chamber spaced apart from each other, so as to separate the cold and hot water as much as possible, thereby increasing the temperature difference between the internal circulation cooling water and the heat exchange unit, and between the cold source and the water to be cooled, thereby increasing the heat exchange capacity, improving the efficiency and reducing the energy consumption.

[0016] (2) The present invention provides a water-cooling system for a main bearing test bench, which connects the cold water chamber and the hot water chamber through a pipeline below the liquid level to ensure that the liquid levels are at the same height, thereby avoiding the evacuation of a single cavity due to different displacements of the cold source and the cold water circulation pump.

[0017] (3) The water cooling system for the main bearing test bench provided by the present invention realizes a wide range of adjustable cooling water flow by configuring the cold water circulation pump to be composed of a plurality of fixed-flow pumps and a variable-flow pump, and by controlling the starting number of the fixed-flow pumps and the displacement of the variable-flow pump, so that the flow regulation is more flexible and the control options are more diverse.

[0018] (4) The present invention provides a water cooling system for a main bearing test bench, which increases the feedback speed adjustment accuracy of the valve group and improves the utilization rate of each channel of the valve group by setting the opening cross-section of each branch proportionally with the branches in the main bearing test bench. At the same time, the rear end of the valve group can have multiple outlets connected to a heat exchange unit branch to expand the flow distribution adjustment range, make the flow adjustment more flexible, and provide more diverse control options, thereby improving efficiency and reducing energy consumption.

[0019] (5) The present invention provides a control method for a water cooling system of a main bearing test bench. The method presets a cooling flow distribution calculation program based on engineering application experience to perform preliminary control of the entire system. Since the preset program may not meet or exceed the actual cooling requirements, the heat coefficient parameters of the flow distribution calculation program are adjusted through temperature feedback with reference to machine learning theory. The heat coefficient parameters that achieve thermal equilibrium under various ambient temperatures and various loading parameters are found and bound to the corresponding ambient temperatures and loading parameters. At the same time, a more accurate heat coefficient can be fed back to support engineering applications. In this way, the control program can be self-corrected to ensure the accuracy and reliability of the control program.

[0020] (6) The present invention provides a control method for a water cooling system of a main bearing test bench. After the heat generation coefficient parameters of the thermal balance are found and bound to the corresponding ambient temperature and loading parameters, the control program is solidified, and the cold water circulation pump and the water distribution unit are adjusted in real time through the back-end temperature feedback to adjust the actual flow of each part of the heat exchange unit; thus, accurate and high feedback speed adaptive adjustment is achieved.

[0021] In addition to the above-described purposes, features and advantages, the present invention has other purposes, features and advantages. The present invention will be further described in detail with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The drawings constituting a part of this application are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings: Figure 1 It is a structural schematic diagram of a water cooling system of a main bearing test bench according to an embodiment of the present invention; Figure 2 It is a schematic flow chart of a water cooling control method for a main bearing test bench according to an embodiment of the present invention; Figure 3 It is a schematic diagram of a process of searching for binding parameters using a water cooling system of a main bearing test bench in an embodiment of the present invention.

[0023] in: 1. Cold source, 2. Water tank, 3. Cold water circulation pump, 4. Water distribution unit, 5. Heat exchange unit, 6. Cooling water circuit, 7. Monitoring unit. DETAILED DESCRIPTION

[0024] In order to make the above-mentioned purposes, features and advantages of the present invention more clear and easy to understand, the specific implementation methods of the present invention are described in detail below in conjunction with the accompanying drawings. It should be noted that the drawings of the present invention are all simplified and use non-precise proportions, which are only used to conveniently and clearly assist in explaining the implementation of the present invention; the "number" mentioned in the present invention is not limited to the specific number in the examples in the accompanying drawings; the directions or positional relationships indicated by "front", "middle", "back", "left", "right", "up", "down", "top", "bottom", "middle", etc. mentioned in the present invention are based on the directions or positional relationships shown in the drawings of the present invention, and do not indicate or imply that the devices or components referred to must have a specific direction, nor can they be understood as limitations on the present invention. Example:

[0025] See also Figure 1 As shown, a water cooling system for a main bearing test bench provided by the present invention comprises a cold source 1, a water tank 2, a cold water circulation pump 3, a water distribution unit 4, a heat exchange unit 5, a cooling water circuit 6 and a monitoring unit 7; The cold source 1 forms a loop with the water tank 2 through a pipeline; The water tank 2 includes a cold water chamber and a hot water chamber which are spaced apart from each other. The cold water chamber is connected to the inner circulation return pipe of the main bearing test bench and the water outlet pipe of the cold source 1. The hot water chamber is connected to the inner circulation water outlet pipe of the main bearing test bench and the water return pipe of the cold source 1. The cold source 1 extracts water from the hot water chamber in the water tank 2, cools it, and then sends it into the cold water chamber of the water tank 2 to achieve circulating cold water cooling. The cold water circulation pump 3 is connected to the water outlet provided on the cold water chamber of the water tank 2, and is used to extract the cooling water in the cold water chamber and send it to the water distribution unit 4. After the cooling water is distributed by the water distribution unit 4, it is sent to various components in the heat exchange unit 5 through various branch pipes provided on the water distribution unit 4 for heat exchange; The water after heat exchange is connected to the cooling water return port of the hot water chamber through the cooling water circuit 6 to be transported to the hot water chamber of the water tank 2.

[0026] The monitoring unit 7 includes a temperature sensor and a water flow sensor. The temperature sensor is provided in multiple pieces and is respectively arranged inside the water tank 2, inside the heat exchange unit 5, and on the cooling water circuit 6 before and after the heat exchange unit 5; the water flow sensor is provided in multiple pieces and is respectively arranged on multiple branch pipes.

[0027] Furthermore, the cold water circulation pump 3 is composed of a fixed-displacement pump and a variable-displacement pump. The test displacement adjustment range is large, and it is extremely difficult for a single variable-displacement pump to cover the entire displacement adjustment range. A combination of multiple fixed-displacement pumps and a variable-displacement pump is used. By controlling the start-up data of the fixed-displacement pump and adjusting the displacement of the variable-displacement pump, they are used in combination to provide more flexibility and control options.

[0028] Furthermore, the water distribution unit 4 is connected with a plurality of branch pipes interconnected with the gear oil branch of the main bearing test bench (in this embodiment, since the bearing under-load operation heat and the bearing gear ring transmission heat are cooled by gear oil, the whole is a separate heat exchange component, therefore, the bearing under-load operation heat and the bearing gear ring transmission heat are defined as a gear oil branch), the reducer branch, the motor group branch and the electrical system branch, and a single branch pipe is provided with a valve group, and the single valve group adjusts its opening through a single electromagnetic force to achieve the regulation of the water flow of the single branch pipe. Furthermore, the heat exchange unit 5 includes a plurality of components corresponding to the plurality of branch pipes (that is, the heat exchange unit 5 includes a gear oil heat exchange component, a reducer heat exchange component, a motor heat exchange component and an electrical system heat exchange component).

[0029] Furthermore, in order to improve the cooling effect, a connecting pipe is provided in the middle upper part of the partition plate used to separate the cold water chamber and the hot water chamber from each other, and the cold water chamber and the hot water chamber are connected to each other below the liquid level through the connecting pipe. Furthermore, since the output flow rates of the water pump connected to the cold source 1 and the cold water circulation pump 3 are different, the liquid levels in the cold water chamber and the hot water chamber are balanced through the internal connecting pipe, avoiding the situation where one side of the chamber is evacuated.

[0030] Furthermore, the water cooling system for a main bearing test bench provided by the present invention also includes a control unit for signal connection of a cold source 1, multiple temperature sensors, multiple water flow sensors, a cold water circulation pump 3 and each electromagnetic force; the control unit includes a control circuit board and a control program that are interconnected.

[0031] As a further embodiment of the present invention, see Figure 2 and Figure 3 As shown, the present invention also provides a control method for a water cooling system of a main bearing test bench, comprising the following steps: Step 1: assemble the water cooling system for the main bearing test bench as described above, and connect the water cooling system for the main bearing test bench with the existing main bearing test bench; Step 2: Take the recommended operating temperature range of the gear oil branch, reducer branch, motor group branch and electrical system branch of the main bearing test bench as the thermal balance target temperature for cooling; And, based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed and maximum test torque of the main bearing test bench during the test, various parameters of the water cooling system of the main bearing test bench are preset; Step 3: Since the preset parameters of the water cooling system of the main bearing test bench may be different from its actual heating situation, the preset parameters may not meet or exceed the cooling requirements. To solve this problem, this embodiment further proposes a control program for automatically modifying the preset parameters; Step 4: operate the water cooling system of the main bearing test bench based on the modified parameters, and adjust the temperature of each water pipe of the water distribution unit 4.

[0032] Furthermore, it is assumed that the recommended operating temperature range of the gear oil branch of the main bearing test bench is set to 60°C, the recommended operating temperature range of the reducer branch is set to 70°C, the recommended operating temperature range of the motor group branch is set to 70°C, and the recommended operating temperature range of the electrical system branch is set to 50°C.

[0033] Furthermore, the thermal balance target temperature of cooling also includes the temperature of the water tank 2, and the temperature of the water tank 2 is specifically set to: 25°C in summer, 20°C in spring and autumn, and 15°C in winter.

[0034] Furthermore, it is worth noting that the thermal equilibrium temperature is related to the working power of each part of the heat exchange unit 5, and the thermal equilibrium temperature is different for different working powers. The temperature mentioned here is only for illustration and is not used as a reference for actual application.

[0035] Furthermore, the specific process of presetting the parameters of the water cooling system of the main bearing test bench is as follows: S2.1, Assume the radius of the test main bearing is , the bearing test axial load is , radial load is The overturning moment is , the bearing raceway friction coefficient is , the main bearing test speed is , the main bearing test torque is , the main bearing ring gear transmission heating coefficient is , the heat generation coefficient of the reducer transmission is , the motor transmission heating coefficient is , the heating coefficient of the electrical system is And the heat dissipation margin factor is ; Preliminary estimate of the heat generation power of the bearing under load , Bearing gear ring transmission heat power , Heat generation power of reducer transmission , Motor transmission heating power , Electrical system heating power , Rated cooling power of cold source 1 and determining the ratio of the opening cross-section size of each branch pipe of the water distribution unit 4; Heat generation power of bearing under load The expression is as follows: ; Bearing gear ring transmission heating power The expression is as follows: ; Heat generation power of reducer transmission The expression is as follows: ; Motor transmission heating power The expression is as follows: ; Electrical system heating power The expression is as follows: ; Rated cooling power of cold source 1 The expression is as follows: ; According to the maximum flow ratio of each branch pipeline corresponding to the multi-way water distribution valve group, the opening cross-sectional size ratio of each branch pipeline of the water distribution unit 4 is set as follows: The ratio of the opening cross-section sizes between the gear oil in the main bearing test bench, the reducer in the main bearing test bench, the motor in the main bearing test bench, and the electrical system in the main bearing test bench is set to: .

[0036] S2.2, Assume that the specific heat capacity of cooling water is , cooling water density is , heat transfer power is , the temperature before heat exchange is And the temperature after heat exchange is , calculate the total cooling water flow of each component in the heat exchange unit 5 ; Cooling water flow The expression is as follows: .

[0037] S2.3, based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed and maximum test torque of the main bearing test bench during the test, and the temperature difference before and after heat exchange obtained in actual engineering applications of the main bearing test bench , taking a more conservative value and substituting it into the equation, we can estimate the maximum flow rate of cooling water required by each component in the heat exchange unit 5 (i.e. the maximum flow rate of the cold water circulation pump 3); Based on the minimum bearing load, minimum radial load, minimum overturning moment, minimum test speed and minimum test torque of the main bearing test bench during the test, and the temperature difference before and after heat exchange obtained in the engineering application of the main bearing test bench , taking a more conservative value and substituting it into the equation, we can estimate the minimum flow rate of cooling water required by each component of the heat exchange unit 5 (ie, the minimum flow rate of the cooling circulation pump 3 ).

[0038] Furthermore, the specific process of automatically modifying the preset parameters is as follows: S3.1. Calculate the actual flow required by each component of the heat exchange unit 5 according to the actual input parameters of the main bearing test bench during the test (including the actual input axial load, the actual input radial load, the actual input overturning moment, the actual input test speed, and the actual output test torque); S3.2, preset the output flow rate of the cold water circulation pump 3 and the cross-sectional dimensions of the branch openings of the water distribution unit 4, and operate the water cooling system of the main bearing test bench based on the preset parameters; At the same time, each water flow sensor detects the actual flow data of each branch pipe in real time and feeds it back to the control program. The control program compares the received actual flow data with the preset water flow data, and adjusts the valve group opening of each branch pipe of the water distribution unit 4 according to the comparison result; When all components of the heat exchange unit 5 reach the set thermal equilibrium target temperature, the current data of each water flow sensor and the data of each temperature sensor are recorded to obtain a first set of temperature data and a first set of water flow data; S3.3, after the water cooling system of the main bearing test bench continues to operate for a period of time based on the first set of temperature data and the first set of water flow data, the data of each corresponding temperature sensor and each water flow sensor are recorded again to obtain a second set of temperature data and a second set of water flow data; S3.4, comparing the first set of temperature data with the second set of temperature data, and adjusting the flow of each branch pipeline based on the comparison result; The specific process is as follows: If the temperature fluctuation range is within ±3℃, no treatment will be done; If the temperature rise range exceeds +3°C, the corresponding heating coefficient is increased and the output flow of the corresponding branch pipeline is recalculated to increase the output flow of the corresponding branch pipeline; If the temperature drops beyond -3°C, the corresponding heating coefficient is reduced and the output flow of the corresponding branch pipeline is recalculated to reduce the output flow of the corresponding branch pipeline; At the same time, the cold water circulation pump 3 and the water distribution unit 4 synchronously adjust the output flow of the cooling circuit and the opening cross-section size of each branch according to the adjustment of the output flow of the corresponding branch pipeline; S3.5. In the process of adjusting the output flow of each branch pipeline based on the comparison results, if the output flow of each branch pipeline has reached the maximum value and the temperature of each component of the heat exchange unit 5 still cannot reach the thermal equilibrium target temperature, the temperature in the cold water chamber in the water tank 2 is cooled down so that the temperature of each component of the heat exchange unit 5 reaches the thermal equilibrium temperature and the final heating coefficients are obtained; at the same time, the current heating coefficients are bound to the corresponding operating parameters and the current heating coefficients are fixed to complete the automatic modification of the preset parameters.

[0039] Furthermore, when cooling the temperature in the cold water chamber in the water tank 2, a single cooling method of 1°C is adopted for gradual cooling, and steps S3.2 and S3.3 are repeated in the process of gradually cooling the temperature in the cold water chamber until the temperatures of the components of the heat exchange unit 5 reach the thermal equilibrium temperature, and the real-time data obtained by the current temperature sensors and water flow sensors are recorded to obtain a third set of temperature data and a third set of water flow data (i.e., the final heating coefficients are obtained).

[0040] Furthermore, after completing the automatic modification of the preset parameters, the heating coefficients are no longer adjusted according to the changes in the temperature data detected by the temperature sensors, and only the output flow of the cold water circulation pump 3 and the water distribution unit 4 is adjusted according to the real-time temperature changes (see S3.5 for the specific adjustment method).

[0041] Furthermore, due to the long service life of the main bearing, the test time corresponding to each working condition is as short as a few days or as long as several months, and it is necessary to refer to the machine learning idea to explore suitable parameters. After the parameters are fixed, the heat number is no longer adjusted according to the temperature change, and the cold water circulation pump 3 and the water distribution unit 4 are adjusted synchronously according to the real-time temperature change. Output flow.

[0042] Furthermore, the temperature control program that loads the binding parameters and starts running is as follows: S4.1. Calculate the required flow of each branch pipeline of the water distribution unit 4 based on the actual input parameters of the main bearing test bench during the test process, preset the opening of each branch pipeline of each valve group according to the required cooling flow, and preset the displacement of the cold water circulation pump 3 according to the sum of the required flow of each branch pipeline; S4.2, the water cooling system of the main bearing test bench starts to operate continuously based on the opening of each branch pipe and the displacement of the cold water circulation pump 3 preset in S4.1, and judges whether the temperature of each component of the heat exchange unit 5 is stable during its continuous operation; If the temperature of each component of the heat exchange unit 5 is equal to the preset temperature, it means that the temperature of each component of the heat exchange unit 5 is in a stable state, that is, the water cooling system of the main bearing test bench continues to operate based on the parameters preset in S4.1; If the temperature of each component of the heat exchange unit 5 is not equal to the preset temperature, it means that the temperature of each component of the heat exchange unit 5 is in an unstable state, that is, the preset temperature is regulated in the following manner: If the temperature of each component of the heat exchange unit 5 is greater than the preset temperature + 3°C, the cold water flow rate of each branch pipe of the water distribution unit 4 is appropriately increased; If the temperature of each component of the heat exchange unit 5 is less than or equal to the preset temperature + 3°C, continue to determine the temperature of each component; If the temperature of each component of the heat exchange unit 5 is lower than the preset temperature of -3°C, the cold water flow rate of each branch pipe of the water distribution unit 4 is appropriately reduced; If the temperature of each component of the heat exchange unit 5 is greater than or equal to the preset temperature -3°C, the system returns to the preset completion point and starts continuous operation to continue operation.

[0043] Furthermore, the adjustment procedure to find the binding parameters to start running is as follows: ①. According to the input test load parameters, the required flow of each branch pipeline is calculated, the distribution valve is preset according to the required cooling flow, and the circulation pump is preset according to the total cooling flow; ②, if the preset flow rate of each branch pipe of the water distribution unit 4 is greater than the maximum flow rate of each branch pipe of the water distribution unit 4, the preset temperature of the water tank 1 is reduced by 1°C, and the flow rate of each branch pipe of the water distribution unit 4 is reduced to return to the calculated required flow node of each branch pipe to re-preset the opening degree of each branch pipe of the water distribution unit 4 and the displacement of the circulating pump; ③. If the flow rate of each branch pipe of the water distribution unit 4 is greater than 1.1 times the calculated preset flow rate of each branch pipe and is not greater than the maximum flow rate of each branch pipe of the water distribution unit 4, the flow rate of each branch pipe of the water distribution unit 4 is appropriately reduced, and the opening degree of each branch pipe of the water distribution unit 4 and the displacement of the circulating pump are reset; ④. If the flow rate of each branch pipe of the water distribution unit 4 is not greater than 1.1 times the calculated preset flow rate of each branch pipe and less than 0.9 times the maximum flow rate of each branch pipe of the water distribution unit 4, the flow rate of each branch pipe of the water distribution unit 4 is appropriately reduced, and the opening degree of each branch pipe of the water distribution unit 4 and the displacement of the circulating pump are reset; ⑤. If the flow rate of each branch pipe of the water distribution unit 4 is not greater than 1.1 times the calculated preset flow rate and not less than 0.9 times the maximum flow rate of each branch pipe of the water distribution unit 4, then the preliminary estimated heating coefficients (including the heating power of the bearing under load operation) are determined. , Bearing gear ring transmission heat power , Heat generation power of reducer transmission , Motor transmission heating power And the heating power of the electrical system ) whether adjustments have been made; If the initially estimated heating coefficients are not adjusted, the system will continue to run until the temperature of each component is equal to the preset temperature; at the same time, the temperature and flow of each corresponding branch pipeline will be recorded, and the temperature and flow of each corresponding branch pipeline will be recorded after a period of stable operation in the next stage; If the initially estimated heating coefficients have been adjusted, the corresponding branch pipe temperatures and flows will be recorded directly after a period of stable operation in the next stage; ⑥. Re-judge whether the temperature of each component is stable; If the temperature of each component is greater than its preset temperature + 2°C, increase each heating coefficient and set its cycle number to 0, and return to step ① to calculate the required flow nodes of each branch pipeline according to the input test load parameters and re-run; If the temperature of each component is not greater than its preset temperature + 2°C, then further determine the temperature of each component. If the temperature of each component is less than its preset temperature - 2°C, then reduce the heating coefficient and set the number of cycles to 0, and return to step ① to calculate the required flow nodes of each branch pipeline according to the input test load parameters and re-run; If the temperature of each component is not greater than its preset temperature +2°C and not less than its preset temperature -2°C, then further determine whether the number of cycles is equal to 5 times; ⑦. If the number of cycles is not equal to 5, then add 1 to the number of cycles, and after a period of stable operation in the next stage, record the corresponding branch pipe temperature and flow, and repeat step ⑥ to determine the temperature of each component and the number of cycles; ⑧. If the number of cycles is equal to 5, each heating parameter is bound to its corresponding working condition.

[0044] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A water cooling system for a main bearing test bench, characterized in that: It comprises a cold source (1), a water tank (2), a cold water circulation pump (3), a water distribution unit (4), a heat exchange unit (5) and a cooling water circuit (6); The cold source (1) forms a cooling circuit with the water tank (2) through pipelines; The water tank (2) comprises a cold water chamber and a hot water chamber which are arranged at intervals from each other, the cold water chamber is connected to the internal circulation water return pipe of the main bearing test bench and the water outlet pipe of the cold source (1), the hot water chamber is connected to the internal circulation water outlet pipe of the main bearing test bench and the water return pipe of the cold source (1), the cold source (1) draws water from the hot water chamber in the water tank (2), cools it, and then sends it into the cold water chamber of the water tank (2); The cold water circulation pump (3) is connected to a water outlet provided on the cold water chamber of the water tank (2) and is used to extract cooling water in the cold water chamber and send it to the water distribution unit (4); the cooling water is distributed by the water distribution unit (4) and then sent to various components in the heat exchange unit (5) through various branch pipes provided on the water distribution unit (4) for heat exchange; The water after heat exchange passes through the cooling water circuit (6) and is connected to the cooling water return port of the hot water chamber so as to be transported to the hot water chamber of the water tank (2).

2. The water cooling system for the main bearing test bench according to claim 1 is characterized in that: Also includes a monitoring unit (7); The monitoring unit (7) comprises a temperature sensor and a water flow sensor. The temperature sensor is provided in multiple pieces and is respectively arranged inside the cold water chamber, inside the heat exchange unit (5), and on the cooling water circuit (6) before and after the heat exchange unit (5). The water flow sensor is provided in multiple pieces and is respectively arranged on multiple branch pipes.

3. The water cooling system for the main bearing test bench according to claim 1 or 2, characterized in that: The water distribution unit (4) is connected to a plurality of branch pipelines for interconnecting with the gear oil, reducer, motor and electrical system of the main bearing test bench, and each branch pipeline is provided with a valve group, and the opening of each valve group is adjusted by a single electromagnetic force.

4. The water cooling system for the main bearing test bench according to claim 3 is characterized in that: It also includes a control unit for signal connection between the cold source (1), a plurality of temperature sensors, a plurality of water flow sensors, a cold water circulation pump (3), and each electromagnetic force; the control unit includes a control circuit board and a control program that are interconnected.

5. A control method for a water cooling system of a main bearing test bench, characterized in that: The following steps are involved: Step 1, assembling the water cooling system for the main bearing test bench as claimed in claim 4, and connecting the water cooling system for the main bearing test bench with the existing main bearing test bench; Step 2: Take the recommended operating temperature range of the gear oil branch, the reducer branch, the motor group branch, the electrical system branch and the water tank (2) of the main bearing test bench as the thermal balance target temperature for cooling; And, based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed and maximum test torque of the main bearing test bench during the test, various parameters of the water cooling system of the main bearing test bench are preset; Step 3: automatically modify the preset parameters according to the actual input parameters of the main bearing test bench during the test, and load and bind the modified parameters into the control program; Step 4: operate the water cooling system of the main bearing test bench based on the modified parameters, and regulate the temperature of each water pipe of the water distribution unit (4).

6. The control method of the water cooling system of the main bearing test bench according to claim 5 is characterized in that: The specific process of presetting the parameters of the water cooling system of the main bearing test bench is as follows: S2.1, Assume the radius of the test main bearing is , the bearing test axial load is , radial load is The overturning moment is , the bearing raceway friction coefficient is , the main bearing test speed is , the main bearing test torque is , the main bearing ring gear transmission heating coefficient is , the heat generation coefficient of the reducer transmission is , the motor transmission heating coefficient is , the heating coefficient of the electrical system is And the heat dissipation margin factor is ; Preliminary estimate of the heat generation power of the bearing under load , Bearing gear ring transmission heat power , Heat generation power of reducer transmission , Motor transmission heating power , Electrical system heating power , Rated cooling power of cooling source (1) and determining the ratio of the opening cross-sectional sizes of the branch pipes of the water distribution unit (4); S2.2, Assume that the specific heat capacity of cooling water is , cooling water density is , heat transfer power is , the temperature before heat exchange is And the temperature after heat exchange is , calculate the total cooling water flow of each component in the heat exchange unit (5) ; S2.3, based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed and maximum test torque of the main bearing test bench during the test, and the temperature difference before and after heat exchange obtained in actual engineering applications of the main bearing test bench , calculate the maximum flow rate of cooling water required by each component in the heat exchange unit (5); Based on the minimum bearing load, minimum radial load, minimum overturning moment, minimum test speed and minimum test torque of the main bearing test bench during the test, and the temperature difference before and after heat exchange obtained in the engineering application of the main bearing test bench , the minimum flow rate of cooling water required by each component of the heat exchange unit (5) is calculated.

7. The control method of the water cooling system of the main bearing test bench according to claim 6 is characterized in that: The specific process of automatically modifying the preset parameters is as follows: S3.

1. Calculating the actual flow required by each component of the heat exchange unit (5) according to the actual input parameters of the main bearing test bench during the test; the actual input parameters include the actual input axial load, the actual input radial load, the actual input overturning moment, the actual input test speed, and the actual output test torque; S3.2, preset the output flow rate of the cold water circulation pump (3) and the cross-sectional dimensions of each branch opening of the water distribution unit (4), and operate the water cooling system of the main bearing test bench based on the preset parameters; At the same time, each water flow sensor detects the actual flow data of each branch pipeline in real time and feeds it back to the control program. The control program compares the received actual flow data with the preset water flow data, and adjusts the valve group opening of each branch pipeline of the water distribution unit (4) based on the comparison result; When all components of the heat exchange unit (5) reach the set thermal equilibrium target temperature, the current data of each water flow sensor and the current data of each temperature sensor are recorded to obtain a first set of temperature data and a first set of water flow data; S3.3, after the water cooling system of the main bearing test bench continues to operate for a period of time based on the first set of temperature data and the first set of water flow data, the data of each corresponding temperature sensor and each water flow sensor are recorded again to obtain a second set of temperature data and a second set of water flow data; S3.4, comparing the first set of temperature data with the second set of temperature data, and adjusting the flow of each branch pipeline based on the comparison result; S3.

5. In the process of adjusting the output flow of each branch pipeline based on the comparison result, if the output flow of each branch pipeline has reached the maximum value and the temperature of each component of the heat exchange unit (5) still cannot reach the thermal equilibrium target temperature, the temperature in the cold water chamber of the water tank (2) is cooled so that the temperature of each component of the heat exchange unit (5) reaches the thermal equilibrium temperature, thereby obtaining the final heating coefficients. At the same time, the current heating coefficients are loaded into the control program and bound to the corresponding operating parameters in the control program and the current heating coefficients are fixed, thereby completing the automatic modification of the preset parameters.

8. The control method of the water cooling system of the main bearing test bench according to claim 7 is characterized in that: The specific process of adjusting the flow of each branch pipeline based on the comparison results is as follows: If the temperature fluctuation range is within ±3℃, no treatment will be done; If the temperature rise range exceeds +3°C, the corresponding heating coefficient is increased and the output flow of the corresponding branch pipeline is recalculated to increase the output flow of the corresponding branch pipeline; If the temperature drops beyond -3°C, the corresponding heating coefficient is reduced and the output flow of the corresponding branch pipeline is recalculated to reduce the output flow of the corresponding branch pipeline; At the same time, the cold water circulation pump (3) and the water distribution unit (4) synchronously adjust the output flow of their cooling circuits and the size of the opening cross-section of each branch according to the adjustment of the output flow of the corresponding branch pipelines.

9. The control method of the water cooling system of the main bearing test bench according to claim 7, characterized in that: When cooling the temperature in the cold water chamber in the water tank (2), the temperature is gradually cooled by 1°C at a time, and steps S3.2 and S3.3 are repeated in the process of gradually cooling the temperature in the cold water chamber until the temperatures of the components of the heat exchange unit (5) reach the thermal equilibrium temperature. The real-time data detected by the current temperature sensors and water flow sensors are recorded to obtain a third set of temperature data and a third set of water flow data, that is, the final heating coefficients.

10. The control method of the water cooling system of the main bearing test bench according to any one of claims 5 to 9, characterized in that: The specific process of regulating the temperature of each water pipe of the water distribution unit (4) is as follows: S4.

1. Calculate the required flow rate of each branch pipeline of the water distribution unit (4) based on the actual input parameters of the main bearing test bench during the test process, preset the opening of each branch pipeline of each valve group according to the required cooling flow rate, and preset the displacement of the cold water circulation pump (3) according to the sum of the required flow rates of each branch pipeline; S4.2, the water cooling system of the main bearing test bench starts to operate continuously based on the openings of the branch pipes and the displacement of the cold water circulation pump (3) preset in S4.1, and judges whether the temperature of each component of the heat exchange unit (5) is stable during the continuous operation; If the temperature of each component of the heat exchange unit (5) is equal to the preset temperature, it means that the temperature of each component of the heat exchange unit (5) is in a stable state, that is, the water cooling system of the main bearing test bench continues to operate based on the parameters preset in S4.1; If the temperature of each component of the heat exchange unit (5) is not equal to the preset temperature, it means that the temperature of each component of the heat exchange unit (5) is in an unstable state, that is, the preset temperature is regulated in the following manner: If the temperature of each component of the heat exchange unit (5) is greater than the preset temperature + 3°C, the cold water flow rate of each branch pipe of the water distribution unit (4) is appropriately increased; If the temperature of each component of the heat exchange unit (5) is less than or equal to the preset temperature + 3°C, continue to determine the temperature of each component; If the temperature of each component of the heat exchange unit (5) is lower than a preset temperature of -3°C, the cold water flow rate of each branch pipe of the water distribution unit (4) is appropriately reduced; If the temperature of each component of the heat exchange unit (5) is greater than or equal to the preset temperature -3°C, the system returns to the preset completion point and starts continuous operation to continue operation.

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