A water cooling system for a main bearing test bench and its control method

Abstract

The present invention provides a water cooling system for a main bearing test bench and its control method, belonging to the technical field of shield machine testing; it includes 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 and the water tank form a cooling circuit; the water tank includes a cold water chamber and a hot water chamber, the cold water chamber is connected to the inner circulation return water pipe of the main bearing test bench and the outlet water 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 return water pipe of the cold source, and the cold source transports the water in the hot water chamber to the cold water chamber; the cooling water in the cold water chamber is distributed by the water distribution unit to each branch pipe and sent to each component in the heat exchange 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 circuit to be transported to the hot water chamber of the water tank. The present invention realizes the automatic cooling of the main bearing test bench during the test by adding a water cooling system to the existing main bearing test bench.

Description

Technical Field

[0001] The invention belongs to the technical field of shield machine test, 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 a tunneling machine, it is necessary to conduct a bench test to ensure the reliability of the main bearing; the main bearing has a large specification and heavy load, and the temperature rises rapidly during the bench test. However, most electro-mechanical-hydraulic systems have certain requirements for the operating temperature, and a cooling system needs to be constructed to control the operating temperature; during the test process, the main things to be controlled include motor heating, reducer heating, ring gear transmission heating, main bearing load operation heating, and electrical system operation heating; considering the equipment operating conditions, heat dissipation requirements and economy, water is a more suitable cooling medium; the equipment has a large heat generation power and requires a large cooling water flow. If it cannot be cooled in time, it will cause the test equipment to stop, or even damage the components. The heat generation power of each part is different, and the required cooling water flow is different. Moreover, this set of system is built for the first time, and there are no accurate heat generation parameters. In order to improve the heat exchange efficiency, reduce energy consumption, and accurately dissipate heat to ensure the operation of the equipment, it is necessary to construct a water cooling system that can adaptively adjust the operating state according to the heat generation of each part of the test bench.

[0003] The existing patent technologies of bearing test benches do not mention the construction of water cooling systems, mainly focusing on the structure. The patents related to cooling mainly focus on fields such as automobiles, computer server units, and refrigeration equipment. By separately setting pumps on each passage to adjust the flow of a single passage, the cost and energy consumption are relatively high, and the space utilization rate is relatively low; the technology of adjusting the flow by controlling the valve opening mainly adjusts according to the difference between the set flow value and the actual flow value, and cannot make an adaptive adjustment according to the temperature. Summary of the Invention

[0004] To solve the problems in the prior art, the invention provides a construction method for a water cooling system of a main bearing test bench of a tunneling machine, a method and a device for adaptively adjusting the operating state according to the heat generation of each part of the test bench, so as to adapt to the different heat generation powers of each part of the test bench and the different required cooling water flows, and adaptively adjust the cooling water demand according to the working conditions.

[0005] The invention provides a water cooling system for a main bearing test bench, including a cold source, a water tank, a cold water circulation pump, a water distribution unit, a heat exchange unit and a cooling water circuit;

[0006] The cold source and the water tank form a cooling circuit through a pipeline;

[0007] The water tank includes a cold water chamber and a hot water chamber that 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, and the hot water chamber is connected to the inner circulation water outlet pipe of the main bearing test bench and the return pipe of the cold source. The cold source extracts the water in the hot water chamber of the water tank, cools it, and then sends it into the cold water chamber of the water tank.

[0008] 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 each component in the heat exchange unit through each branch pipe provided on the water distribution unit for heat exchange.

[0009] The water after heat exchange is connected to the cooling water return port of the hot water chamber through the cooling water circuit, so as to be transported into the hot water chamber of the water tank.

[0010] Further, the water cooling system for the main bearing test bench further includes a monitoring unit.

[0011] The monitoring unit includes a temperature sensor and a water flow sensor. The temperature sensor has multiple pieces respectively arranged inside the cold water chamber, inside the heat exchange unit, and on the cooling water return path before and after the heat exchange unit; the water flow sensor has multiple pieces respectively arranged on multiple branch pipes.

[0012] Optionally, multiple branch pipes for communicating with the gear oil, reducer, motor, and electrical system of the main bearing test bench are connected to the water distribution unit. A valve group is provided on each single branch pipe, and the opening degree of each single valve group is adjusted by a single electromagnetic force.

[0013] Further, the water cooling system for the main bearing test bench further includes a control unit that is signal-connected to the cold source, multiple temperature sensors, multiple water flow sensors, the cold water circulation pump, and each electromagnetic force; the control unit includes a control circuit board and a control program that are connected to each other.

[0014] The present invention also provides a control method for a water cooling system of a main bearing test bench, including the following steps:

[0015] 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 to an existing main bearing test bench.

[0016] Step 2: Take the recommended operating temperature ranges of the gear oil branch, reducer branch, motor set branch, electrical system branch of the main bearing test bench, and the water tank as the heat balance target temperatures for cooling.

[0017] And, based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed, and maximum test torque during the test of the main bearing test bench, preset the parameters of the water cooling system for the main bearing test bench;

[0018] Step 3: Automatically modify the preset parameters according to the actual input parameters during the test of the main bearing test bench, and load and bind the modified parameters to the control program;

[0019] Step 4: Run the water cooling system for the main bearing test bench based on the modified parameters, and regulate the temperature of each water pipeline of the water distribution unit.

[0020] Optionally, the specific process of presetting the parameters of the water cooling system for the main bearing test bench is as follows:

[0021] S2.1. Let the radius of the test main bearing be 、the axial load of the bearing test be 、the radial load be 、the overturning moment be 、the friction coefficient of the bearing raceway be 、the test speed of the main bearing be 、the test torque of the main bearing be 、the heat generation coefficient of the main bearing gear ring drive be 、the heat generation coefficient of the reducer drive be 、the heat generation coefficient of the motor drive be 、the heat generation coefficient of the electrical system be and the heat dissipation margin coefficient be ; preliminarily estimate the heat generation power of the bearing under load operation 、the heat generation power of the bearing gear ring drive 、the heat generation power of the reducer drive 、the heat generation power of the motor drive 、the heat generation power of the electrical system 、the rated refrigeration power of the cold source and determine the proportional size of the opening cross-section of each branch pipeline of the water distribution unit;

[0022] S2.2. Let the specific heat capacity of the cooling water be 、the density of the cooling water be 、the heat exchange power be 、the temperature before heat exchange be and the temperature after heat exchange be , calculate the total cooling water flow rate of each component in the heat exchange unit ;

[0023] S2.3. Based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed, and maximum test torque during the test of the main bearing test bench, and according to the temperature difference before and after heat exchange obtained in the actual engineering application of the main bearing test bench , calculate the maximum flow rate of the cooling water required for each component in the heat exchange unit;

[0024] Based on the minimum bearing load, minimum radial load, minimum overturning moment, minimum test speed, and minimum test torque during the test of the main bearing test bench, and according to 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 the cooling water required for each component of the heat exchange unit.

[0025] Optionally, the specific process of automatically modifying the preset parameters is as follows:

[0026] S3.1. Calculate the actual flow rates required for each component of the heat exchange unit according to the actual input parameters during the test of the main bearing test bench; the actual input parameters include the actually input axial load, actually input radial load, actually input overturning moment, actually input test speed, and actually output test torque;

[0027] S3.2. Preset the output flow rate of the chilled water circulation pump and the opening cross-sectional dimensions of each branch of the water distribution unit, and operate the water cooling system of the main bearing test bench based on the preset parameters;

[0028] Meanwhile, each water flow sensor detects the actual flow rate data of each branch pipeline in real time and feeds it back to the control program. The control program compares the received actual flow rate data with the preset water flow rate data, and adjusts the valve opening of each branch pipeline of the water distribution unit according to the comparison result;

[0029] When each component of the heat exchange unit reaches the set heat balance target temperature, record the data of each current water flow sensor and each temperature sensor to obtain the first set of temperature data and the first set of water flow rate data;

[0030] 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 rate data, record the data of each corresponding temperature sensor and each water flow sensor again to obtain the second set of temperature data and the second set of water flow rate data;

[0031] S3.4. Compare the first set of temperature data with the second set of temperature data, and adjust the flow rate of each branch pipeline based on the comparison result;

[0032] S3.5. During 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 temperatures of the components of the heat exchange unit still cannot reach the thermal equilibrium target temperature, then the temperature in the cold water chamber of the water tank is cooled down so that the temperatures of the components of the heat exchange unit all reach the thermal equilibrium temperature, and the final heat generation coefficients are obtained. At the same time, the current heat generation coefficients are loaded into the control program, bound to the corresponding working condition parameters in the control program, and the current heat generation coefficients are fixed to complete the automatic modification of the preset parameters.

[0033] Optionally, the specific process of adjusting the flow of each branch pipeline based on the comparison result is as follows:

[0034] If its temperature fluctuation range is within ±3°C, no treatment is performed;

[0035] If the rising range of its temperature exceeds +3°C, then increase its corresponding heat generation coefficient and recalculate the output flow of the branch pipeline corresponding thereto to increase the output flow of the corresponding branch pipeline;

[0036] If the falling range of its temperature exceeds -3°C, then decrease its corresponding heat generation coefficient and recalculate the output flow of the branch pipeline corresponding thereto to decrease the output flow of the corresponding branch pipeline;

[0037] At the same time, the cold water circulation pump and the water distribution unit synchronously adjust the output flow of its cooling circuit and the cross-sectional area of the opening of each branch according to the adjustment of the output flow of the corresponding branch pipeline.

[0038] Optionally, when cooling down the temperature in the cold water chamber of the water tank, the method of gradually cooling down by 1°C each time is adopted, and steps S3.2 and S3.3 are repeated during the process of gradually cooling down the temperature in the cold water chamber until the temperatures of the components of the heat exchange unit all reach the thermal equilibrium temperature, and the real-time data detected by the current temperature sensors and water flow sensors are recorded to obtain the third group of temperature data and the third group of water flow data, that is, the final heat generation coefficients are obtained.

[0039] Optionally, the specific process of controlling the temperature of each water pipeline of the water distribution unit is as follows:

[0040] S4.1. Calculate the required flow of each branch pipeline of the water distribution unit based on the actual input parameters during the test of the main bearing test bench. Each valve group presets the opening degree of each branch pipeline according to the cooling required flow, and the cold water circulation pump presets its displacement according to the sum of the required flows of each branch pipeline.

[0041] 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;

[0042] 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;

[0043] 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:

[0044] 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;

[0045] 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;

[0046] 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;

[0047] 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.

[0048] Compared with the prior art, the present invention has the following beneficial effects:

[0049] (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.

[0050] (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.

[0051] (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.

[0052] (4) The water-cooling system for a main bearing test bench provided by the present invention sets the opening cross-sections of each branch in proportion to each branch in the main bearing test bench, so as to improve the adjustment accuracy of the valve group feedback speed, improve the utilization rate of each channel of the valve group. At the same time, multiple outlets at the rear end of the valve group can be connected to one branch of the heat exchange unit, expanding the flow distribution adjustment range, making the flow adjustment more flexible, the control options more diverse, and improving the efficiency and reducing the energy consumption.

[0053] (5) The control method of the water-cooling system for a main bearing test bench provided by the present invention presets a cooling flow distribution calculation program based on engineering application experience to initially control the entire system; since the preset program may not meet or exceed the actual cooling demand, referring to the machine learning theory, by temperature feedback - adjusting the heat generation coefficient parameter of the flow distribution calculation program, find the heat generation coefficient parameter that reaches thermal equilibrium under various ambient temperatures and various loading parameters, bind it with the corresponding ambient temperature and loading parameters, and at the same time, a more accurate heat generation coefficient can be fed back to support engineering applications; thus realizing the self-correction of the control program and ensuring the accuracy and reliability of the control program.

[0054] (6) The control method of the water-cooling system for a main bearing test bench provided by the present invention, after finding the heat generation coefficient parameter that reaches thermal equilibrium and binding it with the corresponding ambient temperature and loading parameters, solidifies the control program, and adjusts the actual flow of each part of the heat exchange unit by adjusting the cold water circulation pump and the water distribution unit in real time through the temperature feedback at the rear end; realizing precise and high-feedback-speed adaptive adjustment.

[0055] In addition to the purposes, features and advantages described above, the present invention has other purposes, features and advantages. The following will refer to the drawings to further elaborate on the present invention in detail. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] The drawings forming a part of this application are used to provide a further understanding of the present invention. The schematic embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation to the present invention. In the drawings:

[0057] Figure 1 is a schematic structural diagram of a water-cooling system for a main bearing test bench in an embodiment of the present invention;

[0058] Figure 2 is a schematic flow diagram of a water-cooling control method for a main bearing test bench in an embodiment of the present invention;

[0059] Figure 3 is a schematic flow diagram of finding and binding parameters of a water-cooling system for a main bearing test bench in an embodiment of the present invention.

[0060] Wherein:

[0061] 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. Specific embodiments

[0062] To make the above objects, features, and advantages of the present invention more clearly understood, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be noted that the drawings of the present invention are all in simplified forms and use non-precise scales, only for the convenience and clarity of assisting in the description of the embodiments of the present invention; the several mentioned in the present invention are not limited to the specific quantities in the drawing examples; the orientation or positional relationships indicated by 'front','middle', 'back', 'left', 'right', 'up', 'down', 'top', 'bottom','middle', etc. in the present invention are all based on the orientation 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 orientation, nor can it be understood as a limitation to the present invention.

[0063] Example:

[0064] See Figure 1 As shown, a water-cooling system for a main bearing test bench provided by the present invention includes 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;

[0065] The cold source 1 forms a circuit with the water tank 2 through a pipeline;

[0066] The water tank 2 includes a cold water chamber and a hot water chamber arranged at intervals. The cold water chamber is connected to the inner circulation return pipe of the main bearing test bench and the outlet pipe of the cold source 1, and the hot water chamber is connected to the inner circulation water outlet pipe of the main bearing test bench and the return pipe of the cold source 1. The cold source 1 extracts the water in the hot water chamber of the water tank 2, cools it, and then sends it into the cold water chamber of the water tank 2 to achieve the cooling of circulating cold water;

[0067] The cold water circulation pump 3 is connected to the water outlet arranged 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 each component in the heat exchange unit 5 through each branch pipeline arranged on the water distribution unit 4 for heat exchange;

[0068] 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 into the hot water chamber of the water tank 2.

[0069] The monitoring unit 7 includes a temperature sensor and a water flow sensor. Multiple pieces of the temperature sensor are 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; multiple pieces of the water flow sensor are respectively arranged on multiple branch pipes.

[0070] Further, 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 one variable-displacement pump is adopted. By controlling the starting data of the fixed-displacement pumps and adjusting the displacement of the variable-displacement pump, they are used in cooperation to provide more flexibility and control options.

[0071] Further, a plurality of branch pipes for communicating with the gear oil branch of the main bearing test bench (in this embodiment, since the heat generated by the bearing running with load and the heat generated by the bearing gear ring transmission are both cooled by the gear oil, and the whole is a single heat exchange component, therefore, the heat generated by the bearing running with load and the heat generated by the bearing gear ring transmission are combined and defined as the gear oil branch), the reducer branch, the motor group branch, and the electrical system branch are connected to the water distribution unit 4. A valve group is provided on each single branch pipe, and each single valve group adjusts its opening degree through a single electromagnetic force to realize the adjustment of the water flow in 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).

[0072] Further, to improve the cooling effect, a connecting pipeline is provided at the middle and upper part of the partition plate for separating the cold water chamber and the hot water chamber, and the cold water chamber and the hot water chamber are interconnected below the liquid levels. 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 reach balance through the internal connecting pipeline, avoiding the situation of unilateral chamber being emptied.

[0073] Further, a water cooling system for a main bearing test bench provided by the present invention further includes a control unit for signal connection to the cold source 1, multiple temperature sensors, multiple water flow sensors, the cold water circulation pump 3, and each electromagnetic force; the control unit includes a control circuit board and a control program connected to each other.

[0074] As a further embodiment of the present invention, refer to 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, including the following steps:

[0075] 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 to the existing main bearing test bench;

[0076] Step 2: Take the recommended operating temperature ranges of the gear oil branch, reducer branch, motor set branch, and electrical system branch of the main bearing test bench as the heat balance target temperatures for cooling;

[0077] Moreover, based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed, and maximum test torque during the test of the main bearing test bench, preset the parameters of the water-cooling system for the main bearing test bench;

[0078] Step 3: Since there may be discrepancies between the preset parameters of the water-cooling system for the main bearing test bench and its actual heat generation situation, the preset parameters may not meet or may exceed the cooling requirements. To solve this problem, this embodiment further proposes a control program for automatically modifying the preset parameters;

[0079] Step 4: Operate the water-cooling system for the main bearing test bench based on the modified parameters, and regulate the temperatures of the water pipelines of the water distribution unit 4.

[0080] Furthermore, set the recommended operating temperature range of the gear oil branch of the main bearing test bench to 60°C, the recommended operating temperature range of the reducer branch to 70°C, the recommended operating temperature range of the motor set branch to 70°C, and the recommended operating temperature range of the electrical system branch to 50°C.

[0081] Furthermore, the heat balance target temperature for cooling also includes the temperature of the water tank 2, and the temperature of the water tank 2 is specifically set as follows: the temperature in summer is 25°C, the temperature in spring and autumn is 20°C, and the temperature in winter is 15°C.

[0082] Even further, it should be noted that the heat balance temperature is related to the operating power of each part of the heat exchange unit 5, and different operating powers result in different heat balance temperatures. The temperatures mentioned here are only for illustrative purposes and are not for actual application reference.

[0083] Furthermore, the specific process of presetting the parameters of the water-cooling system for the main bearing test bench is as follows:

[0084] S2.1: Let the radius of the test main bearing be 、the axial load of the bearing test be 、the radial load be 、the overturning moment be 、the friction coefficient of the bearing raceway be 、the test speed of the main bearing be 、the test torque of the main bearing be , the heat generation coefficient of the main bearing gear ring drive is , the heat generation coefficient of the reducer drive is , the heat generation coefficient of the motor drive is , the heat generation coefficient of the electrical system is and the heat dissipation margin coefficient is ; initially estimate the heat generation power of the bearing under load , the heat generation power of the bearing gear ring drive , the heat generation power of the reducer drive , the heat generation power of the motor drive , the heat generation power of the electrical system , the rated refrigeration power of the cold source 1 and determine the opening cross-sectional area ratio of each branch pipe of the water distribution unit 4;

[0085] The heat generation power of the bearing under load is expressed as follows:

[0086] ;

[0087] The heat generation power of the bearing gear ring drive is expressed as follows:

[0088] ;

[0089] The heat generation power of the reducer drive is expressed as follows:

[0090] ;

[0091] The heat generation power of the motor drive is expressed as follows:

[0092] ;

[0093] The heat generation power of the electrical system is expressed as follows:

[0094] ;

[0095] The rated refrigeration power of the cold source 1 is expressed as follows:

[0096] ;

[0097] Set the opening cross-sectional area ratio of each branch pipe of the water distribution unit 4 according to the maximum flow ratio of each branch pipe corresponding to the multi-way water distribution valve group as follows:

[0098] The ratio of the cross-sectional sizes of the opening between the gear oil in the main bearing test bench, the speed 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 as follows:

[0099] .

[0100] S2.2. Let the specific heat capacity of the cooling water be , the density of the cooling water be , the heat exchange power be , the temperature before heat exchange be and the temperature after heat exchange be , and calculate the total cooling water flow of each component in the heat exchange unit 5;

[0101] The cooling water flow has the following expression:

[0102] .

[0103] S2.3. Based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed, and maximum test torque during the test of the main bearing test bench, and according to the temperature difference before and after heat exchange obtained in the actual engineering application of the main bearing test bench, take a more conservative value and substitute it to estimate the maximum flow rate of the cooling water required for each component in the heat exchange unit 5 (i.e., the maximum flow rate of the cold water circulation pump 3);

[0104] Based on the minimum bearing load, minimum radial load, minimum overturning moment, minimum test speed, and minimum test torque during the test of the main bearing test bench, and according to the temperature difference before and after heat exchange obtained in the engineering application of the main bearing test bench, take a more conservative value and substitute it to estimate the minimum flow rate of the cooling water required for each component in the heat exchange unit 5 (i.e., the minimum flow rate of the cooling circulation pump 3).

[0105] Furthermore, the specific process of automatically modifying the preset parameters is as follows:

[0106] S3.1. According to the actual input parameters during the test of the main bearing test bench (including the actually input axial load, actually input radial load, actually input overturning moment, actually input test speed, and actually output test torque), calculate the actual flow rate required for each component of the heat exchange unit 5;

[0107] S3.2. Preset the output flow rate of the cold water circulation pump 3 and the opening cross-sectional dimensions of each branch of the water distribution unit 4, and operate the water cooling system of the main bearing test bench based on the preset parameters;

[0108] Meanwhile, 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 of each branch with the preset water flow data of each branch, and adjusts the valve opening of each branch pipeline of the water distribution unit 4 according to the comparison result;

[0109] When all components of the heat exchange unit 5 reach the set heat balance target temperature, record the data of each current water flow sensor and each temperature sensor to obtain the first set of temperature data and the first set of water flow data;

[0110] S3.3. After the water cooling system of the main bearing test bench runs for a period of time based on the first set of temperature data and the first set of water flow data, record the data of each corresponding temperature sensor and each water flow sensor again to obtain the second set of temperature data and the second set of water flow data;

[0111] S3.4. Compare the first set of temperature data with the second set of temperature data, and adjust the flow rate of each branch pipeline based on the comparison result;

[0112] The specific process is as follows:

[0113] If the temperature fluctuation range is within ±3°C, no treatment is required;

[0114] If the rising range of the temperature exceeds +3°C, increase its corresponding heating coefficient and recalculate the output flow rate of the corresponding branch pipeline to increase the output flow rate of the corresponding branch pipeline;

[0115] If the falling range of the temperature exceeds -3°C, decrease its corresponding heating coefficient and recalculate the output flow rate of the corresponding branch pipeline to decrease the output flow rate of the corresponding branch pipeline;

[0116] Meanwhile, the cold water circulation pump 3 and the water distribution unit 4 synchronously adjust the output flow rate of its cooling circuit and the cross-sectional area of each branch opening according to the adjustment of the output flow rate of the corresponding branch pipeline;

[0117] S3.5. During the process of adjusting the output flow rate of each branch pipeline based on the comparison result, if the output flow rate 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 heat balance target temperature, then cool down the temperature in the cold water chamber of the water tank 2 so that the temperature of each component of the heat exchange unit 5 reaches the heat balance temperature to obtain the final heating coefficients of each branch; at the same time, bind the current heating coefficients to their corresponding working condition parameters and fix the current heating coefficients of each branch to complete the automatic modification of the preset parameters.

[0118] Further, when cooling the temperature in the cold water chamber of the water tank 2, the temperature is gradually reduced by 1°C each time, and steps S3.2 and S3.3 are repeated during the process of gradually reducing the temperature in the cold water chamber until the temperatures of all components of the heat exchange unit 5 reach the thermal equilibrium temperature, and the real-time data detected by each current temperature sensor and each water flow sensor are recorded to obtain the third set of temperature data and the third set of water flow data (i.e., obtaining the final heat generation coefficients).

[0119] Further, after automatically modifying the preset parameters, the heat generation coefficients are no longer adjusted according to the changes in the temperature data detected by each temperature sensor, and only the output flows of the cold water circulation pump 3 and the water distribution unit 4 are adjusted according to the real-time temperature changes (for the specific adjustment method, see S3.5).

[0120] Further, since the main bearing has a long service life and the test time corresponding to each working condition is short for several days and long for several months, there is a need to explore appropriate parameters with reference to the machine learning idea. After the parameters are fixed, the heat generation is no longer adjusted according to the temperature change, and the output flows of the cold water circulation pump 3 and the water distribution unit 4 are synchronously adjusted according to the real-time temperature change.

[0121] Further, the temperature control program for starting operation by loading the bound parameters is as follows:

[0122] S4.1. Calculate the required flow rates of the branch pipes of the water distribution unit 4 based on the actual input parameters during the test of the main bearing test bench, preset the opening degrees of the branch pipes by each valve group according to the cooling required flow rate, and preset the displacement of the cold water circulation pump 3 according to the sum of the required flow rates of the branch pipes;

[0123] S4.2. The water cooling system of the main bearing test bench starts continuous operation based on the opening degrees of the branch pipes preset in S4.1 and the displacement of the cold water circulation pump 3, and determines whether the temperatures of all components of the heat exchange unit 5 are stable during its continuous operation;

[0124] If the temperatures of all components of the heat exchange unit 5 are equal to the preset temperature, it means that the temperatures of all components of the heat exchange unit 5 are 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;

[0125] If the temperatures of all components of the heat exchange unit 5 are not equal to the preset temperature, it means that the temperatures of all components of the heat exchange unit 5 are in an unstable state, that is, the preset temperature is regulated in the following manner:

[0126] If the temperatures of all components of the heat exchange unit 5 are greater than the preset temperature + 3°C, appropriately increase the cold water flow rates of the branch pipes of the water distribution unit 4;

[0127] If the temperature of each component of the heat exchange unit 5 is less than or equal to the preset temperature + 3°C, then continue to judge the temperature of each component;

[0128] If the temperature of each component of the heat exchange unit 5 is less than the preset temperature - 3°C, then appropriately reduce the cold water flow rate of each branch pipeline of the water distribution unit 4;

[0129] If the temperature of each component of the heat exchange unit 5 is greater than or equal to the preset temperature - 3°C, then return to the node of continuous operation after presetting and continue to operate.

[0130] Furthermore, the adjustment procedure for finding the binding parameters to start running is as follows:

[0131] ①. Calculate the required flow rate of each branch pipeline according to the input test load parameters. The distribution valve presets the opening degree of each branch pipeline according to the required cooling flow rate, and the circulation pump presets the displacement according to the total required cooling flow rate;

[0132] ②. If the preset flow rate of each branch pipeline of the water distribution unit 4 is greater than the maximum flow rate of each branch pipeline of the water distribution unit 4, then reduce the preset temperature of the water tank 1 by 1°C and reduce the flow rate of each branch pipeline of the water distribution unit 4 to return to the node of the required flow rate of each branch pipeline calculated and re-preset the opening degree of each branch pipeline of the water distribution unit 4 and the displacement of the circulation pump;

[0133] ③. If the flow rate of each branch pipeline of the water distribution unit 4 is greater than 1.1 times the preset flow rate of each branch pipeline calculated and not greater than the maximum flow rate of each branch pipeline of the water distribution unit 4, then appropriately reduce the flow rate of each branch pipeline of the water distribution unit 4 and re-preset the opening degree of each branch pipeline of the water distribution unit 4 and the displacement of the circulation pump;

[0134] ④. If the flow rate of each branch pipeline of the water distribution unit 4 is not greater than 1.1 times the preset flow rate of each branch pipeline calculated and less than 0.9 times the maximum flow rate of each branch pipeline of the water distribution unit 4, then appropriately reduce the flow rate of each branch pipeline of the water distribution unit 4 and re-preset the opening degree of each branch pipeline of the water distribution unit 4 and the displacement of the circulation pump;

[0135] ⑤. If the flow rate of each branch pipeline 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 pipeline of the water distribution unit 4, then judge whether the initially estimated heat generation coefficients (i.e., including the heat generation power of the bearing under load operation 、the heat generation power of the bearing gear ring transmission 、the heat generation power of the reducer transmission 、the heat generation power of the motor transmission and the heat generation power of the electrical system ) have been adjusted;

[0136] If the preliminary estimated heat generation coefficients of each component are not adjusted, continue to operate until the temperature of each component is equal to the preset temperature; meanwhile, record the temperature and flow rate of each branch pipeline corresponding at present, and record the temperature and flow rate of each branch pipeline corresponding after stabilizing operation for a period of time in the next stage;

[0137] If the preliminary estimated heat generation coefficients of each component have been adjusted, directly record the temperature and flow rate of each branch pipeline corresponding after stabilizing operation for a period of time in the next stage;

[0138] ⑥. Re-judge whether the temperature of each component is stable;

[0139] If the temperature of each component is greater than its preset temperature + 2°C, increase each heat generation coefficient and set its cycle number to 0, and return to step ① to recalculate the required flow rate nodes of each branch pipeline according to the input test load parameters and run again;

[0140] If the temperature of each component is not greater than its preset temperature + 2°C, further judge the temperature of each component. If the temperature of each component is less than its preset temperature - 2°C, decrease the heat generation coefficient and set its cycle number to 0, and return to step ① to recalculate the required flow rate nodes of each branch pipeline according to the input test load parameters and run again;

[0141] If the temperature of each component is not greater than its preset temperature + 2°C and not less than its preset temperature - 2°C, further judge whether its cycle number is equal to 5 times;

[0142] ⑦. If the cycle number is not equal to 5 times, increase the cycle number by 1, record the temperature and flow rate of each branch pipeline corresponding after stabilizing operation for a period of time in the next stage, and repeat step ⑥ to judge the temperature of each component and the cycle number;

[0143] ⑧. If the cycle number is equal to 5 times, bind each heat parameter to its corresponding working condition.

[0144] The above are only the preferred embodiments of the present invention and are not used to limit the present invention. For those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A control method for a water cooling system of a main bearing test bench, characterized in that, It includes the following steps: Step 1: Assemble the water-cooling system for the main bearing test bench and connect the water-cooling system for the main bearing test bench to the existing main bearing test bench; The water-cooling system for the main bearing test bench includes 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) and the water tank (2) form a cooling circuit through a pipeline; The water tank (2) includes a cold water chamber and a hot water chamber that are arranged at intervals. The cold water chamber is connected to the inner circulation return pipe of the main bearing test bench and the outlet pipe of the cold source (1), and the hot water chamber is connected to the inner circulation water outlet pipe of the main bearing test bench and the return pipe of the cold source (1). The cold source (1) extracts the water in the hot water chamber of the water tank (2) and cools it before sending it into the cold water chamber of the water tank (2); 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 being distributed by the water distribution unit (4), the cooling water is sent to each component in the heat exchange unit (5) through each branch pipeline 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 into the hot water chamber of the water tank (2); Step 2: Take the recommended operating temperature ranges of the gear oil branch, the reducer branch, the motor set branch, the electrical system branch of the main bearing test bench, and the water tank (2) as the heat balance target temperatures for cooling; Moreover, based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed, and maximum test torque during the test of the main bearing test bench, preset each parameter of the water-cooling system for the main bearing test bench; Step 3: Automatically modify each preset parameter according to the actual input parameters during the test of the main bearing test bench, and load and bind the modified parameters to the control program; The specific process of automatically modifying each preset parameter is as follows: S3.1: Calculate the actual flow rates required for each component of the heat exchange unit (5) according to the actual input parameters during the test of the main bearing test bench; the actual input parameters include the actual input axial load, actual input radial load, actual input overturning moment, actual input test speed, and 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 openings of each branch of the water distribution unit (4), and operate the water-cooling system for the main bearing test bench based on the preset parameters; At the same time, each water flow sensor detects the actual flow rate data of each branch pipeline in real time and feeds it back to the control program. The control program compares the received actual flow rate data with the preset water flow rate data and adjusts the valve opening of each branch pipeline of the water distribution unit (4) according to the comparison result; When all components of the heat exchange unit (5) reach the set target temperature of thermal equilibrium, record the data of each current water flow sensor and each temperature sensor to obtain the first set of temperature data and the 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, record the data of each corresponding temperature sensor and each water flow sensor again to obtain the second set of temperature data and the second set of water flow data; S3.

4. Compare the first set of temperature data with the second set of temperature data, and adjust the flow rate of each branch pipeline based on the comparison result; S3.

5. During the process of adjusting the output flow rate of each branch pipeline based on the comparison result, if the output flow rate 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 target temperature of thermal equilibrium, then cool down the temperature in the cold water chamber of the water tank (2) so that the temperature of each component of the heat exchange unit (5) reaches the thermal equilibrium temperature, and obtain the final heat generation coefficients of each; at the same time, load the current heat generation coefficients into the control program, bind them to the corresponding working condition parameters in the control program, and fix the current heat generation coefficients of each, thus completing the automatic modification of the preset parameters; Step Four. Operate the water cooling system of the main bearing test bench based on the modified parameters, and regulate the temperature of each water pipeline of the water distribution unit (4).

2. The control method of the water cooling system for the main bearing test bench according to claim 1, characterized in that, The specific process of presetting each parameter of the water cooling system of the main bearing test bench is as follows: S2.

1. Set the radius of the test main bearing as R, the axial load of the bearing test as F a , the radial load as F r , the overturning moment as M k , the friction coefficient of the bearing raceway as u0, the rotational speed of the main bearing test as n0, the torque of the main bearing test as T0, the heat generation coefficient of the main bearing ring drive as K1, the heat generation coefficient of the reducer drive as K2, the heat generation coefficient of the motor drive as K3, the heat generation coefficient of the electrical system as K4, and the heat dissipation margin coefficient as h; preliminarily estimate the heat generation power P0 of the bearing under load operation, the heat generation power P1 of the main bearing ring drive, the heat generation power P2 of the reducer drive, the heat generation power P3 of the motor drive, the heat generation power P4 of the electrical system, the rated refrigeration power P of the cold source (1) l and determine the proportionality of the opening cross-sectional areas of the branch pipes of the water distribution unit (4); S2.

2. Set the specific heat capacity of the cooling water as C, the density of the cooling water as ρ, the heat exchange power as P i 、 the temperature before heat exchange as T1 and the temperature after heat exchange as T2, and calculate the total cooling water flow rate Q of each component in the heat exchange unit (5) i ; S2.

3. Based on the maximum axial load, maximum radial load, maximum overturning moment, maximum test speed, and maximum test torque during the test of the main bearing test bench, calculate the maximum flow rate of the cooling water required for each component in the heat exchange unit (5) according to the temperature difference (T2 - T1) before and after heat exchange obtained in the actual engineering application of the main bearing test bench; Based on the minimum bearing load, minimum radial load, minimum overturning moment, minimum test speed, and minimum test torque during the test of the main bearing test bench, calculate the minimum flow rate of the cooling water required for each component in the heat exchange unit (5) according to the temperature difference (T2 - T1) before and after heat exchange obtained in the engineering application of the main bearing test bench.

3. The control method of the water cooling system for the main bearing test bench according to claim 1, characterized in that, The specific process of adjusting the flow rate of each branch pipeline based on the comparison result is as follows: If the temperature fluctuation range is within ±3°C, no treatment is performed; If the rising range of its temperature exceeds +3°C, then increase its corresponding heat generation coefficient and recalculate the output flow rate of the corresponding branch pipeline to increase the output flow rate of the corresponding branch pipeline; If the falling range of its temperature exceeds -3°C, then decrease its corresponding heat generation coefficient and recalculate the output flow rate of the corresponding branch pipeline to decrease the output flow rate 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 rate of their cooling circuits and the cross-sectional area of the openings of each branch according to the adjustment of the output flow rate of the corresponding branch pipeline.

4. The control method of the water cooling system for the main bearing test bench according to claim 1, characterized in that When cooling the temperature in the cold water chamber of the water tank (2), the temperature is gradually reduced by 1 °C each time, and steps S3.2 and S3.3 are repeated during the process of gradually reducing the temperature in the cold water chamber until the temperatures of all components of the heat exchange unit (5) reach the thermal equilibrium temperature. Record the real-time data detected by each current temperature sensor and each water flow sensor to obtain the third set of temperature data and the third set of water flow data, that is, obtain the final heat generation coefficients of each component.

5. The control method of the water cooling system for the main bearing test bench according to any one of claims 1-4, characterized in that, The specific process of regulating the temperatures of each water pipeline of the water distribution unit (4) is as follows: S4.

1. Calculate the required flow rates of each branch pipeline of the water distribution unit (4) based on the actual input parameters during the test of the main bearing test bench. Each valve group presets the opening degrees of each branch pipeline according to the cooling required flow rate, and the cold water circulation pump (3) presets its displacement 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 continuous operation based on the opening degrees of each branch pipeline preset in S4.1 and the displacement of the cold water circulation pump (3), and determines whether the temperatures of all components of the heat exchange unit (5) are stable during its continuous operation. If the temperatures of all components of the heat exchange unit (5) are equal to the preset temperature, it means that the temperatures of all components of the heat exchange unit (5) are 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 temperatures of all components of the heat exchange unit (5) are not equal to the preset temperature, it means that the temperatures of all components of the heat exchange unit (5) are in an unstable state, that is, the preset temperature is regulated in the following manner: If the temperatures of all components of the heat exchange unit (5) are greater than the preset temperature + 3 °C, appropriately increase the cold water flow rate of each branch pipeline of the water distribution unit (4). If the temperatures of all components of the heat exchange unit (5) are less than or equal to the preset temperature + 3 °C, continue to judge the temperatures of all components. If the temperatures of all components of the heat exchange unit (5) are less than the preset temperature - 3 °C, appropriately reduce the cold water flow rate of each branch pipeline of the water distribution unit (4). If the temperatures of all components of the heat exchange unit (5) are greater than or equal to the preset temperature - 3 °C, return to the node of starting continuous operation after presetting and continue to operate.

6. The control method of the water cooling system for the main bearing test bench according to claim 5, characterized in that, The water cooling system of the main bearing test bench further includes a monitoring unit (7); The monitoring unit (7) includes temperature sensors and water flow sensors. Multiple temperature sensors are 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); multiple water flow sensors are respectively arranged on multiple branch pipelines.

7. The control method of the water cooling system for the main bearing test bench according to claim 6, characterized in that, Multiple branch pipelines for communicating with the gear oil, reducer, motor, and electrical system of the main bearing test bench are connected to the water distribution unit (4). A valve group is provided on each single branch pipeline, and each single valve group adjusts its opening degree through a single electromagnetic force.

8. The control method of the water cooling system for the main bearing test bench according to claim 7, characterized in that, The water cooling system for the main bearing test bench further includes a control unit that is signal-connected to the cold source (1), multiple temperature sensors, multiple water flow sensors, the cold water circulation pump (3), and each electromagnetic force; the control unit includes a control circuit board and a control program that are connected to each other.

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