High-speed driving control system and double-loop redundancy control method

Abstract

The invention relates to a high-speed driving control system and a double-loop redundancy control method, a speed driving unit is electrically connected with a motor unit, an Ethernet and hard wire double-loop communication interface is designed, and the speed regulation of the motor unit is realized; the motor unit outputs specified driving power according to a driving instruction of the speed driving unit; the gear speed increasing unit is directly connected with the output end of the motor, is used for transmitting and increasing the rotating speed of the motor and providing high-speed rotating driving power for the system, and has vibration speed signal and gear bearing temperature detection functions; the lubricating and cooling unit is used for lubricating and cooling a running gear bearing in the gear speed increasing unit and monitoring the lubricating oil temperature, the oil pressure, the oil way blockage, the oil liquid level and the oil pump running in real time; the control unit integrates control logics of all the units and controls the whole high-speed driving control system to operate according to the high-speed rotation test driving requirements of turbine pump components. Feature identification of early fault symptoms of the system is realized, and the problem of lagging response of a slowly-changing parameter to a high-speed running fault is solved.

Description

Technical Field

[0001] The invention belongs to the technical field of cold test of liquid rocket engines and relates to a high-speed drive control system and a dual-loop redundant control method. Background Art

[0002] The turbo pump is one of the main components of a liquid rocket engine. It consists of an inducer, a pump centrifugal wheel, a turbine, bearings, seals, a shaft support system, and a housing. Its working principle is to use high-temperature and high-pressure gas to drive the turbine, which drives the pump to rotate to achieve pressurized input of liquid propellant components. The turbo pump operates at a speed of tens of thousands of revolutions per minute. In order to reduce the risk of failure, long-term high-speed ground rotation tests are usually carried out on its bearings, seals, turbines, pumps and other rotating components to study the life and reliability of each component.

[0003] There are two common drive modes for high-speed rotation tests of turbine pump components: motor drive and turbine drive. Since the turbine drive consumes a lot of gas and is difficult to operate for a long time, a motor connected to a gear speed increaser (generally referred to as a high-speed drive system) is usually used. The high-speed drive system has a high output speed, high power, and long operating time. Once an abnormality occurs, personnel will not have time to remedy it, and it will cause a major safety accident. Therefore, a reliable control system and control method are needed to ensure the continuous and smooth operation of the system. Conventional drive control systems have the following problems:

[0004] (1) Delayed fault response function: Conventional drive control systems only monitor slowly changing parameters such as temperature and pressure. When these parameters show abnormalities, it is already in the middle or late stage of system failure, and protection intervention cannot be carried out early.

[0005] (2) Insufficient safety design of each component unit: The high-speed drive system is generally composed of a speed drive unit, a motor unit, a gear speed increase unit, a lubrication and cooling unit, a control unit, etc. The conventional drive system only monitors conventional parameters such as gearbox temperature and lubricating oil pressure to implement alarms or shutdowns. It lacks protective design inside each subunit, which is not conducive to the long-term operation of the system at high speed.

[0006] (3) Single control method: The control of conventional drive systems basically relies on the CPU software program. Once the communication fails or the program is blocked, all control measures will fail, causing the system to run out of control. Summary of the invention

[0007] The technical problem solved by the present invention is: to overcome the deficiencies of the prior art, to propose a high-speed drive control system and a dual-loop redundant control method, to realize characteristic recognition of early system fault signs, to solve the problem of delayed response of slowly varying parameters to high-speed operation faults, to comprehensively monitor the operating status and key parameters of each component unit of the system while improving the internal operation safety of the unit.

[0008] The technical solution of the present invention is: a high-speed drive control system, the component units include a speed drive unit, a motor unit, a gear speed increasing unit, a lubrication cooling unit and a control unit;

[0009] The speed drive unit is electrically connected to the motor unit, and an Ethernet and hard-wired dual-circuit communication interface is designed to achieve speed regulation and control of the motor unit;

[0010] The motor unit outputs the specified driving power according to the driving instruction of the speed driving unit, and is directly connected to the gear speed increasing unit to realize high-speed rotation power output;

[0011] The gear speed increasing unit is directly connected to the output end of the motor unit, used to transmit and increase the motor speed, provide high-speed rotation driving power for the system, and has multi-channel vibration speed signal detection function and various levels of gear bearing temperature detection function;

[0012] The lubrication and cooling unit lubricates and cools the high-speed gear bearings in the gear speed increasing unit, and monitors the lubrication oil temperature, oil pressure, oil line blockage, oil level, and oil pump operation in real time;

[0013] The control unit monitors the operating status parameters of the speed drive unit, motor unit, gear speed increase unit, and lubrication cooling unit in real time, integrates the control logic of each component unit, and controls the entire high-speed drive control system to operate according to the high-speed rotation test drive requirements of the turbine pump components.

[0014] Furthermore, the speed driving unit integrates power devices for rectification and inversion, and adopts an AC-DC-AC method to output a PWM wave with adjustable duty cycle to drive the motor unit and realize on-demand adjustment of the motor speed;

[0015] The speed drive unit is designed with complete operation protection functions, including motor thermal protection, stall protection, underload protection, phase loss protection, and communication fault protection;

[0016] The speed drive unit interacts with command words through the Ethernet loop on the one hand, and interacts with IO through the DI / DO / AI / AO hard-wired loop on the other hand. When one of the communication loops is abnormal, the other communication loop is switched to ensure the controllable operation of the motor unit.

[0017] Furthermore, the motor unit includes a motor body, an encoder, a cooling fan, an electric heater, and a PTC;

[0018] The motor body outputs the corresponding driving power according to the PWM wave output by the speed drive unit, and the current speed of the motor is fed back in real time through the encoder; the cooling fan is turned on before the motor is started to assist the heat dissipation during the operation of the motor; the electric heater prevents moisture condensation inside the equipment when the air humidity is high; the PTC thermistor temperature sensing head is pre-buried in the motor stator winding. When the motor is operating normally, the PTC is in a low resistance state with a resistance value of less than 1.5kohm; when the motor is overheated due to a fault, the PTC resistance value jumps due to heat, and the resistance value is greater than 4kohm. The control unit detects the fault signal, outputs the fault information, and controls the motor to stop running.

[0019] Further, the gear speed increasing unit includes a plurality of gear box temperature sensors and a plurality of gear box vibration sensors;

[0020] The gearbox temperature sensor is used to monitor the operating temperature of the low-speed end gear, low-speed end bearing, high-speed end gear, and high-speed end bearing in real time; the gearbox vibration sensor is used to monitor the dynamic speed of the gear speed increase unit in real time and transmit it to the control unit.

[0021] Further, the lubrication and cooling unit includes an oil pump, an oil flow meter, oil temperature sensors T9-T10, an oil pressure sensor, an oil filter, and an oil level meter;

[0022] Before the system is started, the oil pump is turned on to establish oil pressure and oil circulation; the oil pressure sensor and oil flow meter are used to measure the oil supply line pressure and flow respectively; during system operation, the oil temperature sensors T9 and T10 are used to monitor the oil inlet temperature and the oil outlet temperature respectively. When the oil inlet temperature and / or the oil outlet temperature exceeds the upper working limit, an alarm or shutdown protection is implemented; when the oil filter detects blockage, the built-in DO point is used to output the blockage status; the oil level gauge is used to measure the oil level in the oil tank and detect the low output oil level state.

[0023] Furthermore, the control unit is provided with a local / remote selection switch for switching between local mode and remote mode. In the local mode, it supports real-time feedback of the operating status of each component unit of the system, which is used in the system debugging and troubleshooting stages; in the remote mode, it provides an operation control interface and a parameter display interface for each component unit of the system, which is used in the formal operation stage of the system;

[0024] The speed drive unit is provided with a hard line / communication selection switch for switching between hard line mode and communication mode. In the hard line mode, the speed drive unit and the control unit exchange information through an analog signal line; in the communication mode, the speed drive unit and the control unit exchange information through an EtherNet digital link.

[0025] Further, the control unit includes a remote HMI panel, a local operation panel, a local status indication, a thermal protection element, a vibration analysis module, a CPU and an IO module;

[0026] The remote HMI panel communicates with the CPU and IO module through the CANopen bus and works in remote mode, providing operation control interface and parameter display interface for each component unit of the system; the control decision logic of the drive unit, motor unit, gear speed increase unit, and lubrication and cooling unit are integrated in the CPU, and output is executed through the IO module; the local operation panel and local status indication work in local mode and are used in the system debugging and troubleshooting stage; the thermistor protection device is used to detect the PTC status of the motor unit, and the vibration analysis module is used to perform spectrum analysis on the speed signal transmitted by the gear speed increase unit, and set the alarm and emergency stop graded protection thresholds within the system operation base frequency, double frequency, and triple frequency bands.

[0027] Furthermore, the control decision logic of the control unit includes:

[0028] During the startup or operation phase, the speed drive unit integrates the internal power supply, communication, and operation fault information with OR logic, outputs a drive ready signal or a drive fault signal, and transmits it back to the control unit through Ethernet or a hard-wired loop. The control unit decides whether to allow startup or to protect the shutdown.

[0029] The control unit detects the running status of the motor unit cooling fan and the PTC output status in real time, and decides whether the speed drive unit is allowed to start or stop for protection;

[0030] The control unit detects the operation of the lubrication and cooling unit oil pump and the blockage status of the oil filter, as well as the oil temperature, oil pressure, oil filter, and oil level information in real time, and decides whether the speed drive unit allows starting or protection stopping;

[0031] During the operation stage, the gearbox vibration sensor of the gear speed increasing unit transmits vibration speed information to the vibration analysis module at a high response frequency. The vibration analysis module performs spectrum analysis on the vibration speed parameters, extracts early fault sign characteristics, decides on the alarm shutdown state, and issues intervention instructions in time. At the same time, the control unit monitors the temperature sensor parameters of gear bearings at all levels in real time and decides on intervention measures.

[0032] Furthermore, the drive ready signal and the drive fault signal are transmitted to the control unit CPU via Ethernet and hard line;

[0033] The operation status of the cooling fan and oil pump is connected to the CPU DI input point through a circuit breaker with double auxiliary contacts for control decision logic judgment on the one hand, and to the hardware logic circuit for electrical logic judgment on the other hand, so as to realize the start and stop decision control of the drive control system;

[0034] The thermistor of the PTC of the motor unit is detected by the thermistor protection element. The thermistor protection element has dual status outputs. On the one hand, it is connected to the CPU DI input point for control decision logic judgment, and on the other hand, it is connected to the hardware logic circuit for electrical logic judgment to realize abnormal decision control of the motor unit;

[0035] The vibration signal of the gear speed increasing unit is analyzed by the vibration analysis module for spectrum analysis, and the alarm and emergency stop status of early faults are determined. The output of the vibration analysis module is divided into two electrical circuits. On the one hand, it is connected to the CPU DI input point for control decision logic judgment, and on the other hand, it is connected to the hardware logic circuit for electrical logic judgment to realize abnormal vibration decision control;

[0036] The oil pressure, oil level, oil flow and oil filter all use sensor devices with dual DO status outputs, and the fault status is connected to the CPU DI input point for control decision logic judgment on the one hand, and to the hardware logic circuit for electrical logic judgment on the other hand, to realize lubrication abnormality decision.

[0037] A dual-loop redundant control method for a high-speed drive control system comprises the following steps:

[0038] In the preparation stage, the local / remote selector switch is turned to the remote mode, and the hardwire / communication selector switch is turned to the communication mode;

[0039] Before operation, start the cooling fan of the motor unit, start the oil pump of the lubrication cooling unit, and start the speed drive unit;

[0040] Set the system target operating speed;

[0041] The system starts and enters the self-test procedure: check in sequence that the speed drive unit is ready and has no faults; check that the cooling fan of the motor unit is running and the motor PTC output is normal; check that the vibration speed feedback of the gear speed increase unit is normal and the bearing temperatures of all levels of gears are normal; check that the oil pump of the lubrication and cooling unit is running, the oil filter is not blocked, and the oil temperature, oil pressure, and oil level feedback are normal; if the above self-test conditions are met, the motor runs at the set target speed;

[0042] During high-speed operation, the control unit detects the operating parameter status of each component unit through CPU control logic and hard-wire dual-channel detection, and implements emergency stop protection measures for drive failure, power surge, fan failure, PTC failure, oil pump failure, oil filter blockage and low oil level failure. It implements a hierarchical protection strategy of low limit alarm and high limit emergency stop for abnormal conditions such as low oil pressure, high gear shaft temperature, high vibration speed and high oil temperature.

[0043] After the system runs for a specified period of time, the motor stops running;

[0044] Turn off the speed drive unit, turn off the lubrication cooling unit oil pump, and turn off the cooling fan.

[0045] The beneficial effects of the present invention compared with the prior art are:

[0046] (1) The present invention adds dynamic parameter monitoring to the high-speed gear speed increasing unit to achieve characteristic recognition of early system fault signs, solve the problem of delayed response of slowly varying parameters to high-speed operation faults, and handle the faults in a timely manner in the early stages to avoid further losses caused by fault degradation.

[0047] (2) The present invention improves the internal operation safety of each component unit of the system by fully designing the internal safety of each component unit, and comprehensively displays the operating status and key parameters of each component unit of the system, thereby improving the maintainability of the system.

[0048] (3) The present invention adopts a dual-loop redundant monitoring method, that is, the control and operation of the system are guaranteed by the dual output of software control logic and hardware. Specifically, a set of fully functional hardware control circuits are designed according to the software control process. While the software is monitoring in real time, the hardware control circuit is activated synchronously to ensure that the control instructions are effectively output and the system operation is safe and controllable.

[0049] (4) The present invention takes into account that during the high-speed operation of the turbine pump components, there may be abnormal situations in which the power of the drive system surges due to product friction. The control unit also adds a power surge emergency stop protection function, which implements emergency stop protection for the system by customizing the protection threshold of a power surge of y kilowatts within x seconds. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Figure 1 This is a schematic diagram of the composition principle of a high-speed drive control system according to an embodiment of the present invention;

[0051] Figure 2 A control decision logic diagram of a control unit according to an embodiment of the present invention;

[0052] Figure 3 A schematic diagram of a high-speed rotation test driving process of a turbine pump component according to an embodiment of the present invention;

[0053] In the figure: 1-speed drive unit; 2-motor unit, 21-motor body, 22-encoder, 23-cooling fan, 24-electric heater, 25-PTC; 3-gear speed increasing unit, 31-gear box temperature sensor T1~T8, 32-gear box vibration sensor Z1~Z4; 4-lubrication cooling unit, 41-oil pump, 42-oil flow meter; 43-oil temperature sensor T9~T10, 44-oil pressure sensor, 45-oil filter, 46-oil level meter; 5-control unit, 51-remote HMI panel, 52-CPU and IO module, 53-local operation panel, 54-local status indication, 55-LT3SM00ED thermistor protection element, 56-VSE100 vibration analysis module. DETAILED DESCRIPTION

[0054] The present invention proposes a high-speed drive control system, which improves the timeliness of system fault processing and ensures the operation safety inside the unit by adding dynamic parameter monitoring and safety design inside each component unit of the system. The component units of the high-speed drive control system include a speed drive unit, a motor unit, a gear speed increasing unit, a lubrication cooling unit and a control unit.

[0055] The speed drive unit is a direct action unit for driving the motor. It integrates power electronic devices for rectification and inversion. It drives the motor and adjusts the motor output speed through AC-DC-AC PWM (Pulse Width Modulation). The speed drive unit integrates complete power supply, communication, operation and other safety protection functions. The Ethernet and hard-wired dual-circuit communication mode is designed to ensure reliable communication between units.

[0056] The motor unit is a unit that converts electrical energy into rotational mechanical energy. The main body of the unit is a three-phase asynchronous motor. The output end is mechanically connected to the gear speed increase unit to provide a rotational power source for the system. The motor unit is equipped with protective devices such as a cooling fan, a PTC (Positive Temperature Coefficient), and an electric heater to ensure that the motor works normally within a reasonable temperature range.

[0057] The gear speed increasing unit is directly connected to the motor output end, used to transmit and increase the motor speed, and provide high-speed rotation driving power for the system. The gear speed increasing unit is equipped with a one-way vibration sensor to realize the vibration speed signal detection function, which can detect fault signs early and improve the timeliness of fault handling; the gear bearing temperature sensors at all levels are added to realize the gear bearing temperature detection function at all levels, which can protect the gears and bearings from heat damage due to high-speed operation.

[0058] The lubrication and cooling unit lubricates and cools the high-speed gears and bearings in the gear speed increasing unit, relieves component fatigue, and increases component life. The lubricating oil temperature, oil pressure, oil line blockage, oil level, and oil pump operation are all monitored in real time, effectively displaying the operating status of each component inside the unit and ensuring the safety of the unit's internal operation.

[0059] The control unit is the control core of the entire high-speed drive system. It monitors the operating status and operating parameters of each component unit in real time and combines the test process to form a comprehensive control decision method to ensure the continuous and reliable operation of the high-speed drive system. The control unit also provides a friendly human-machine operation interface.

[0060] The control unit 5 is provided with a local / remote selection switch for switching between local mode and remote mode. Figure 3 The control operations shown and the real-time feedback of the corresponding operating status are mostly used in the system debugging and troubleshooting stages. In remote mode, operation control interfaces and parameter display interfaces for each component unit of the system are provided, which are mostly used in the formal operation stage of the system.

[0061] The speed drive unit 1 is provided with a hardwire / communication selection switch for switching between hardwire mode and communication mode. In the hardwire mode, the speed drive unit 1 and the control unit 5 exchange information through an analog signal line; in the communication mode, the speed drive unit 1 and the control unit 5 exchange information through an EtherNet digital link.

[0062] The present invention accordingly proposes a dual-loop redundant control method for a high-speed drive control system, which is applied to the driving process of a high-speed rotation test of a turbine pump component, and includes the following steps:

[0063] Step 1: During the preparation phase, make sure that the local / remote selector switch is set to remote mode, and that the hardwire / communication selector switch is set to communication mode;

[0064] Step 2: Before operation, start the cooling fan of the motor unit, start the oil pump of the lubrication cooling unit, and start the speed drive unit;

[0065] Step 3: Set the system target operating speed;

[0066] Step 4: Start the system and enter the self-test program: check in sequence that the speed drive unit is ready and has no faults; check that the cooling fan of the motor unit is running and the motor PTC output is normal; check that the vibration speed feedback of the gear speed increase unit is normal and the bearing temperatures of all levels of gears are normal; check that the oil pump of the lubrication and cooling unit is running, the oil filter is not blocked, and the oil temperature, oil pressure, and oil level feedback are normal; if the above self-test conditions are met, the motor runs at the set target speed, otherwise a self-test problem prompt will be displayed on the human-machine interface;

[0067] Step 5: During high-speed operation, the control unit detects the operating parameter status of each component unit through CPU control logic and hard-line dual-channel detection, and implements emergency stop protection measures for key abnormal faults such as drive failure, power surge, fan failure, PTC failure, oil pump failure, oil filter blockage, low oil level, etc.; implements a hierarchical protection strategy of low limit alarm and high limit emergency stop for abnormal conditions such as low oil pressure, high gear shaft temperature, high vibration speed, high oil temperature, etc.;

[0068] Step 6: After the system runs for a specified period of time, the motor stops running;

[0069] Step 7: Turn off the speed drive unit, turn off the lubrication cooling unit oil pump, and turn off the cooling fan.

[0070] The present invention will be further described below in conjunction with the embodiments.

[0071] Example 1

[0072] In this embodiment, by fully designing the electrical safety of each component unit of the system, the internal operation safety of the unit is improved, and the operation status and key parameters of each component unit of the system are fully displayed to improve the maintainability of the system. In particular, dynamic parameter monitoring technology is added to the high-speed gear speed increase unit, and spectrum analysis is carried out to extract early fault signs, set spectrum segment hierarchical control strategy, and prevent fault degradation.

[0073] like Figure 1 As shown, in this embodiment, a high-speed drive control system is proposed, which includes a speed drive unit 1, a motor unit 2, a gear speed increasing unit 3, a lubrication and cooling unit 4, and a control unit 5. Among them, the speed drive unit 1 is electrically connected to the motor unit 2, and an Ethernet and hard-wired dual-loop communication interface is designed to realize the speed regulation and control of the motor unit 2; the motor unit 2 outputs the specified driving power according to the driving instruction of the speed drive unit 1, and is mechanically directly connected to the gear speed increasing unit 3 to realize the high-speed rotation power output; the gear speed increasing unit 3 is directly connected to the output end of the motor unit, which is used to transmit and increase the motor speed, provide the system with high-speed rotation driving power, and has a multi-channel vibration speed signal detection function and a gear bearing temperature detection function at all levels; the lubrication and cooling unit 4 lubricates and cools the high-speed running gear bearings in the gear speed increasing unit 3, and monitors the lubricating oil temperature, oil pressure, oil circuit blockage, oil level, and oil pump operation in real time; the control unit 5 monitors the operating state parameters of the speed drive unit 1, the motor unit 2, the gear speed increasing unit 3, and the lubrication and cooling unit 4 in real time, integrates the control logic of all the above components, and controls the entire high-speed drive control system to operate according to the high-speed rotation test drive requirements of the turbine pump components.

[0074] In this embodiment, the speed drive unit 1 integrates power devices for rectification and inversion, and adopts an AC-DC-AC mode to output a PWM wave with adjustable duty cycle to drive the motor unit and realize the on-demand adjustment of the motor speed. The speed drive unit is designed with complete operation protection functions, including motor thermal protection, stall protection, underload protection, phase loss protection, communication fault protection, etc., and a custom setting interface is reserved for the above functions. In addition, in order to ensure the reliability of communication between units, ensure the normal issuance of control instructions and the normal return of drive parameters, an Ethernet and hard-wired dual-loop communication interface is designed. On the one hand, the instruction word interaction is carried out through the Ethernet loop, and on the other hand, the IO interaction is carried out through the DI / DO / AI / AO hard-wired loop. When one of the communication loops is abnormal, the other communication loop can be flexibly switched to ensure the controllable operation of the motor unit.

[0075] In this embodiment, the motor unit 2 includes a motor body 21, an encoder 22, a cooling fan 23, an electric heater 24, and a PTC 25. The motor body 21 is a three-phase asynchronous motor, which outputs corresponding driving power according to the PWM command wave output by the speed drive unit 1, and feeds back the current motor speed in real time through the encoder 22. The cooling fan 23 is turned on before the motor is started to assist in heat dissipation during the operation of the motor. The electric heater 24 prevents moisture from condensing inside the device when the air humidity is high.

[0076] The thermistor temperature sensing head of PTC25 is embedded in the stator winding of the motor. When the motor is operating normally, the PTC is in a low resistance state (resistance value <1.5kohm); when the motor is overheated due to a fault, the PTC thermal resistance value jumps (resistance value >4kohm), and the LT3SM00ED thermistor protection element 55 of the control unit 5 detects the fault signal, outputs the fault information, and controls the motor to stop running. The use of PTC25 allows the motor to disconnect the circuit before approaching the insulation heat resistance grade temperature, which effectively guarantees the safe operation of the unit.

[0077] In this embodiment, the gear speed increasing unit 3 is mechanically connected to the output end of the motor unit 2 to transmit and increase the motor speed and provide high-speed rotation driving power for the system. It includes T1~T8 gear box temperature sensors 31 and Z1~Z4 gear box vibration sensors 32; T1~T8 gear box temperature sensors 31 are used to monitor the operating temperature of low-speed end gears, low-speed end bearings, high-speed end gears, and high-speed end bearings in real time. Considering that the temperature signal is a slowly varying parameter, it reflects that it is already in the middle and late stages of the rotation fault when it is abnormal, and it is impossible to intervene early to prevent the fault from further deteriorating. Z1~Z4 gear box vibration sensors 32 are added to monitor the dynamic speed of the gear speed increasing unit in real time, and the speed signal is analyzed by the VSE100 vibration analysis module 56 of the control unit 5 to set the alarm and emergency stop graded protection thresholds within the system operation base frequency, double frequency, and triple frequency bands.

[0078] In this embodiment, the lubrication and cooling unit 4 is used to lubricate and cool the high-speed running gears and bearings in the gear speed increasing unit 3, and includes an oil pump 41, an oil flow meter 42, a T9-T10 oil temperature sensor 43, an oil pressure sensor 44, an oil filter 45, and an oil level meter 46. Before the system is started, the oil pump 41 is first turned on to establish the oil pressure and oil circuit circulation. The oil pressure sensor 44 and the oil flow meter 42 are used to measure the pressure and flow of the oil supply circuit respectively. During the operation of the system, the oil temperature sensors T9 and T10 are used to monitor the oil inlet temperature and the oil outlet temperature respectively. When the oil inlet temperature and / or the oil outlet temperature exceeds the upper limit of the working, an alarm or shutdown protection is implemented. When the oil filter 45 detects blockage, the built-in DO point is used to output the blockage state. The oil level meter 46 is used to measure the oil level in the oil tank and detect the low state of the output oil level.

[0079] In this embodiment, the hardware of the control unit 5 mainly includes a remote HMI panel 51, a CPU and an IO module 52, a local operation panel 53, a local status indication 54, an LT3SM00ED thermistor protection element 55, and a VSE100 vibration analysis module 56. The remote HMI panel 51 communicates with the CPU and the IO module 52 via the CANopen bus, and works in remote mode, providing an operation control interface and a parameter display interface for each component unit of the system. The control decision logic of the drive unit 1, the motor unit 2, the gear speed increasing unit 3, and the lubrication and cooling unit 4 are integrated inside the CPU, and the output is executed through the IO module. The local operation panel 53 and the local status indication 54 are used in the system local mode, which is mostly used in the system debugging and troubleshooting stages. The LT3SM00ED thermistor protection element 55 is used to detect the state of the motor PTC25, and the VSE100 vibration analysis module 56 is used for the spectrum analysis of the dynamic speed of the gearbox.

[0080] like Figure 2 As shown, the control decision logic implemented by the control unit 5 in a start-stop cycle is as follows:

[0081] (1) During the startup or operation phase, the speed drive unit 1 integrates the internal power supply, communication, operation and other fault information with OR logic, outputs a drive ready signal or a drive fault signal, and transmits it back to the control unit 5 via Ethernet or a hard-wired loop. The control unit 5 decides whether to allow startup or to stop the vehicle for protection.

[0082] (2) The control unit 5 detects the fan operation status of the motor unit and the PTC output status of the motor in real time, and decides whether the speed drive unit is allowed to start or stop for protection.

[0083] (3) The control unit 5 detects in real time the operation of the lubrication and cooling unit oil pump 41 and the blockage status of the oil filter 44, as well as parameter information such as oil temperature, oil pressure, oil filter, and oil level, and decides whether the speed drive unit 1 is allowed to start or to stop for protection.

[0084] (4) During the operation phase, the gearbox vibration sensor 32 added to the gear speed increasing unit 3 transmits vibration velocity parameter information to the VSE100 vibration analysis module 56 at a high response frequency. The VSE100 vibration analysis module 56 performs spectrum analysis on the vibration velocity parameters, extracts early fault symptom characteristics, determines the alarm shutdown state, and issues intervention instructions in a timely manner. At the same time, the control unit 5 monitors the temperature sensor parameters of the gear bearings at all levels in real time and determines the intervention measures.

[0085] In this embodiment, the dual-loop redundant control method adopted can ensure the normal issuance of system control instructions and the timely feedback of operating parameters through the dual output of hardware and software, thereby fully ensuring the controllable operation of the system.

[0086] The drive ready signal and drive fault signal can be transmitted to the control unit CPU via Ethernet and hard line. The operation status of the cooling fan 23 and the oil pump 41 is connected to the CPU DI input point for software program logic judgment on the one hand, and to the hardware logic circuit for electrical logic judgment on the other hand, so as to realize the start and stop decision control of the drive control system. The thermistor of the motor PTC25 is detected by the LT3SM00ED thermal protection element 55. The thermal protection element 55 has a dual-channel state output. On the one hand, it is connected to the CPU DI input point for software program logic judgment, and on the other hand, it is connected to the hardware logic circuit for electrical logic judgment to realize the abnormal decision control of the motor unit 2. The vibration signal of the gear speed increase unit 3 is subjected to spectrum analysis by the VSE100 vibration analysis module 56, and the alarm and emergency stop status of the early fault are determined. The output of the vibration analysis module 56 is divided into two electrical lines, and on the one hand, it is connected to the CPU DI input point for software program logic judgment, and on the other hand, it is connected to the hardware logic circuit for electrical logic judgment to realize the abnormal vibration decision control. The oil pressure, oil level, oil flow and oil filter all use sensor devices with dual DO status outputs, and the fault status is connected to the CPU DI input point for software program logic judgment on the one hand, and to the hardware logic circuit for electrical logic judgment on the other hand, to achieve abnormal lubrication decision-making.

[0087] Figure 3 The schematic diagram of the driving process of the embodiment of the present invention applied to the high-speed rotation test of the turbine pump components is schematically shown. Specifically, the following steps are included:

[0088] Step 1: System preparation stage: select remote mode for formal system operation, and isolate man and machine; select local mode for debugging or troubleshooting. Generally, select communication mode, and select hard line mode when communication fails.

[0089] Step 2: Start the auxiliary equipment: start the motor unit cooling fan 23, start the lubrication cooling unit oil pump 41, and start the speed drive unit 1.

[0090] Step 3: Set the system target speed on the remote HMI panel 51.

[0091] Step 4: System startup: Press the start button on the remote HMI panel 51, and the system will automatically self-check: check the speed drive unit 1 drive is ready and has no faults; check the motor unit cooling fan 23 is running and the motor PTC 25 output is normal; check the gear speed increase unit 3 vibration speed feedback is normal and the bearing temperature of each gear is normal; check the lubrication cooling unit 4 oil pump is running, the oil filter 45 is not blocked, and the oil temperature, oil pressure, and oil level feedback are normal. If the above self-check conditions are met, the motor runs at the set target speed, otherwise the self-check problem item prompt will be displayed on the remote HMI panel 51.

[0092] Step 5: During the system operation: the control unit 5 detects the operating parameter status of each subunit through the CPU control logic and hard line dual-channel. For key abnormal faults such as drive failure, power surge, fan failure, PTC failure, oil pump failure, oil filter blockage, low oil level, etc., implement emergency stop protection decisions. For abnormal conditions such as low oil pressure, high gear shaft temperature, high vibration speed, high oil temperature, etc., implement low limit alarm, high limit emergency stop hierarchical protection decisions.

[0093] Step 6: Normal drive shutdown: After the system runs for a specified period of time, click the stop button and the motor stops running.

[0094] Step 7: Shut down auxiliary equipment: turn off the speed drive unit, turn off the oil pump, and turn off the cooling fan.

[0095] In this embodiment, the parameters involved in the decision and the parameter triggering thresholds are shown in Table 1. A hierarchical decision method is implemented for some faults: a minor fault warning prompt is given, and the system can continue to operate; a more stringent shutdown protection decision is taken for a serious fault.

[0096] Table 1 Parameters involved in decision-making and parameter triggering thresholds

[0097]

[0098] In summary, the present invention provides a high-speed drive control system and a dual-loop redundant control method for ground testing of turbine pump components. The high-speed drive control system adds a dynamic parameter monitoring function to the high-speed gear speed increaser unit to achieve characteristic recognition of early system fault signs and solve the problem of delayed response of slowly varying parameters to high-speed operation faults. At the same time, the internal safety design of each component unit of the system is fully carried out to improve the internal operation safety of the unit while comprehensively monitoring the operating status and key parameters of each component unit of the system. The proposed control method also adopts a dual-loop redundant control method to back up a complete set of hardware control circuits based on the software control logic. When the system is abnormal, it can be processed through the software process on the one hand, and the hardware electrical protection measures can be directly activated on the other hand. The dual output of software and hardware is used to ensure the effective output of control instructions and the safe operation of the system.

[0099] Although the present invention has been disclosed as above in the form of a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications to the technical solution of the present invention by using the methods and technical contents disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention shall fall within the protection scope of the technical solution of the present invention.

[0100] The contents not described in detail in the specification of the present invention belong to the common knowledge of those skilled in the art.

Claims

1. A high-speed drive control system, characterized in that: The component units include a speed driving unit, a motor unit, a gear speed increasing unit, a lubrication and cooling unit and a control unit; The speed drive unit is electrically connected to the motor unit, and an Ethernet and hard-wired dual-circuit communication interface is designed to achieve speed regulation and control of the motor unit; The motor unit outputs the specified driving power according to the driving instruction of the speed driving unit, and is directly connected to the gear speed increasing unit to realize high-speed rotation power output; The gear speed increasing unit is directly connected to the output end of the motor unit, used to transmit and increase the motor speed, provide high-speed rotation driving power for the system, and has multi-channel vibration speed signal detection function and various levels of gear bearing temperature detection function; The lubrication and cooling unit lubricates and cools the high-speed gear bearings in the gear speed increasing unit, and monitors the lubrication oil temperature, oil pressure, oil line blockage, oil level, and oil pump operation in real time; The control unit monitors the operating status parameters of the speed drive unit, motor unit, gear speed increase unit, and lubrication cooling unit in real time, integrates the control logic of each component unit, and controls the entire high-speed drive control system to operate according to the high-speed rotation test drive requirements of the turbine pump components.

2. A high-speed drive control system according to claim 1, characterized in that: The speed drive unit integrates power devices for rectification and inversion, and uses an AC-DC-AC method to output a PWM wave with adjustable duty cycle to drive the motor unit and realize on-demand adjustment of the motor speed; The speed drive unit is designed with complete operation protection functions, including motor thermal protection, stall protection, underload protection, phase loss protection, and communication fault protection; The speed drive unit interacts with command words through the Ethernet loop on the one hand, and interacts with IO through the DI / DO / AI / AO hard-wired loop on the other hand. When one of the communication loops is abnormal, the other communication loop is switched to ensure the controllable operation of the motor unit.

3. A high-speed drive control system according to claim 2, characterized in that: The motor unit includes a motor body, an encoder, a cooling fan, an electric heater, and a PTC; The motor body outputs the corresponding driving power according to the PWM wave output by the speed drive unit, and the current speed of the motor is fed back in real time through the encoder; the cooling fan is turned on before the motor is started to assist the heat dissipation during the operation of the motor; the electric heater prevents moisture condensation inside the equipment when the air humidity is high; the PTC thermistor temperature sensing head is pre-buried in the motor stator winding. When the motor is operating normally, the PTC is in a low resistance state with a resistance value of less than 1.5kohm; when the motor is overheated due to a fault, the PTC resistance value jumps due to heat, and the resistance value is greater than 4kohm. The control unit detects the fault signal, outputs the fault information, and controls the motor to stop running.

4. A high-speed drive control system according to claim 3, characterized in that: The gear speed increasing unit includes a plurality of gear box temperature sensors and a plurality of gear box vibration sensors; The gearbox temperature sensor is used to monitor the operating temperature of the low-speed end gear, low-speed end bearing, high-speed end gear, and high-speed end bearing in real time; the gearbox vibration sensor is used to monitor the dynamic speed of the gear speed increase unit in real time and transmit it to the control unit.

5. A high-speed drive control system according to claim 4, characterized in that: The lubrication and cooling unit includes an oil pump, an oil flow meter, oil temperature sensors T9-T10, an oil pressure sensor, an oil filter, and an oil level meter; Before the system is started, the oil pump is turned on to establish oil pressure and oil circulation; the oil pressure sensor and oil flow meter are used to measure the oil supply line pressure and flow respectively; during system operation, the oil temperature sensors T9 and T10 are used to monitor the oil inlet temperature and the oil outlet temperature respectively. When the oil inlet temperature and / or the oil outlet temperature exceeds the upper working limit, an alarm or shutdown protection is implemented; when the oil filter detects blockage, the built-in DO point is used to output the blockage status; the oil level gauge is used to measure the oil level in the oil tank and detect the low output oil level state.

6. A high-speed drive control system according to claim 5, characterized in that: The control unit is provided with a local / remote selection switch for switching between local mode and remote mode. In the local mode, it supports real-time feedback of the operating status of each component unit of the system, which is used in the system debugging and troubleshooting stages; in the remote mode, it provides an operation control interface and a parameter display interface for each component unit of the system, which is used in the formal operation stage of the system; The speed drive unit is provided with a hard line / communication selection switch for switching between hard line mode and communication mode. In the hard line mode, the speed drive unit and the control unit exchange information through an analog signal line; in the communication mode, the speed drive unit and the control unit exchange information through an EtherNet digital link.

7. A high-speed drive control system according to claim 6, characterized in that: The control unit includes a remote HMI panel, a local operation panel, a local status indicator, a thermal protection element, a vibration analysis module, a CPU and an IO module; The remote HMI panel communicates with the CPU and IO module through the CANopen bus and works in remote mode, providing operation control interface and parameter display interface for each component unit of the system; the control decision logic of the drive unit, motor unit, gear speed increase unit, and lubrication and cooling unit are integrated in the CPU, and output is executed through the IO module; the local operation panel and local status indication work in local mode and are used in the system debugging and troubleshooting stage; the thermistor protection device is used to detect the PTC status of the motor unit, and the vibration analysis module is used to perform spectrum analysis on the speed signal transmitted by the gear speed increase unit, and set the alarm and emergency stop graded protection thresholds within the system operation base frequency, double frequency, and triple frequency bands.

8. A high-speed drive control system according to claim 7, characterized in that: The control decision logic of the control unit includes: During the startup or operation phase, the speed drive unit integrates the internal power supply, communication, and operation fault information with OR logic, outputs a drive ready signal or a drive fault signal, and transmits it back to the control unit through Ethernet or a hard-wired loop. The control unit decides whether to allow startup or to protect the shutdown. The control unit detects the running status of the motor unit cooling fan and the PTC output status in real time, and decides whether the speed drive unit is allowed to start or stop for protection; The control unit detects the operation of the lubrication and cooling unit oil pump and the blockage status of the oil filter, as well as the oil temperature, oil pressure, oil filter, and oil level information in real time, and decides whether the speed drive unit allows starting or protection stopping; During the operation stage, the gearbox vibration sensor of the gear speed increasing unit transmits vibration speed information to the vibration analysis module at a high response frequency. The vibration analysis module performs spectrum analysis on the vibration speed parameters, extracts early fault sign characteristics, decides on the alarm shutdown state, and issues intervention instructions in time. At the same time, the control unit monitors the temperature sensor parameters of gear bearings at all levels in real time and decides on intervention measures.

9. A high-speed drive control system according to claim 8, characterized in that: The drive ready signal and the drive fault signal are transmitted to the control unit CPU via Ethernet and hard line; The operation status of the cooling fan and oil pump is connected to the CPU DI input point through a circuit breaker with double auxiliary contacts for control decision logic judgment on the one hand, and to the hardware logic circuit for electrical logic judgment on the other hand, so as to realize the start and stop decision control of the drive control system; The thermistor of the PTC of the motor unit is detected by the thermistor protection element. The thermistor protection element has dual status outputs. On the one hand, it is connected to the CPU DI input point for control decision logic judgment, and on the other hand, it is connected to the hardware logic circuit for electrical logic judgment to realize abnormal decision control of the motor unit; The vibration signal of the gear speed increasing unit is analyzed by the vibration analysis module for spectrum analysis, and the alarm and emergency stop status of early faults are determined. The output of the vibration analysis module is divided into two electrical circuits. On the one hand, it is connected to the CPU DI input point for control decision logic judgment, and on the other hand, it is connected to the hardware logic circuit for electrical logic judgment to realize abnormal vibration decision control; The oil pressure, oil level, oil flow and oil filter all use sensor devices with dual DO status outputs, and the fault status is connected to the CPU DI input point for control decision logic judgment on the one hand, and to the hardware logic circuit for electrical logic judgment on the other hand, to realize lubrication abnormality decision.

10. A dual-loop redundant control method for a high-speed drive control system based on the system of claims 1 to 9, characterized in that: The following steps are involved: In the preparation stage, the local / remote selector switch is turned to the remote mode, and the hardwire / communication selector switch is turned to the communication mode; Before operation, start the cooling fan of the motor unit, start the oil pump of the lubrication cooling unit, and start the speed drive unit; Set the system target operating speed; The system starts and enters the self-test program: check the speed drive unit in turn to see if the drive is ready and has no faults; Check that the cooling fan of the motor unit is running and the motor PTC output is normal; Check that the vibration speed feedback of the gear speed increasing unit is normal and the bearing temperature of each gear is normal; check that the oil pump of the lubrication and cooling unit is running, the oil filter is not blocked, and the oil temperature, oil pressure and oil level feedback are normal; if the above self-test conditions are met, the motor runs at the set target speed; During high-speed operation, the control unit detects the operating parameter status of each component unit through CPU control logic and hard-wire dual-channel detection, and implements emergency stop protection measures for drive failure, power surge, fan failure, PTC failure, oil pump failure, oil filter blockage and low oil level failure. It implements a hierarchical protection strategy of low limit alarm and high limit emergency stop for abnormal conditions such as low oil pressure, high gear shaft temperature, high vibration speed and high oil temperature. After the system runs for a specified period of time, the motor stops running; Turn off the speed drive unit, turn off the lubrication cooling unit oil pump, and turn off the cooling fan.

Images