Integrated intelligent verification system and method of diesel generator speed regulation system

Abstract

The invention provides an integrated intelligent verification system and method for a diesel generator speed regulation system. The system comprises a mechanical speed regulation testboard, an electronic speed regulation testboard and an intelligent verification device. The intelligent verification device comprises an upper computer device and a lower computer device. The upper computer equipment is used for simulating and outputting the working mode of the diesel generator and providing test working parameters for the electronic speed regulator and the mechanical speed regulator based on the working mode of the diesel generator; the lower computer equipment is respectively connected with the upper computer equipment, the electronic speed regulator, the mechanical speed regulation control box and the detection equipment, and is used for correspondingly sending test working parameters to the electronic speed regulator and the mechanical speed regulator, and collecting working state parameters of the electronic speed regulator and working state parameters of the mechanical speed regulator to the upper computer equipment in real time; and the upper computer device displays and analyzes the working state parameters so as to verify the electronic speed regulator and the mechanical speed regulator. According to the invention, off-line test verification can be carried out on the diesel generator speed regulation system.

Description

Technical Field

[0001] The invention of the present application relates to the technical field of nuclear power equipment manufacturing, and in particular to an integrated intelligent calibration system and method for a diesel generator speed control system. Background Art

[0002] As an important safety equipment in nuclear power plants, nuclear power emergency power generation diesel generators are closely related to nuclear power safety. In the event of an emergency, emergency diesel generators can serve as emergency power sources to stop the reactor normally and protect key equipment from damage, playing a vital role in ensuring nuclear power safety. Practice has shown that once a nuclear power plant fails, if the emergency diesel generator cannot start normally and provide high-quality electricity, the consequences will be disastrous.

[0003] The diesel generator speed control system is the most important control system for nuclear power emergency power generation diesel generators. Just like the human brain controls actions to meet requirements based on information received from the outside world and as needed, for diesel generators, it accepts external requirements and compares the current working status of the diesel generator to control the start of the diesel generator, stabilize the speed and output high-quality power output that meets the requirements, so that the generator can output the required electricity.

[0004] At present, the diesel generator speed control system can only be tested on site by actually running the diesel generator to see if the function of the speed control system meets the requirements, resulting in high operating costs and high risks. Once a faulty speed control system is actually tested on site, it may cause damage to the diesel generator body, such as runaway and overload operation. Therefore, it is very necessary to conduct a comprehensive and maximum possible test of the speed control system in the laboratory or workshop to ensure the smooth progress of the diesel generator test and improve the availability and reliability of the diesel generator. Summary of the invention

[0005] The present application provides an integrated intelligent calibration system and method for a diesel generator speed control system, which are used to perform offline testing and calibration on the diesel generator speed control system.

[0006] In a first aspect, an integrated intelligent calibration system for a diesel generator speed regulation system provided by an embodiment of the present application includes: a mechanical speed regulation test bench, an electronic speed regulation test bench, and an intelligent calibration device; the mechanical speed regulation test bench includes a mechanical governor, a mechanical speed regulation transmission box for controlling the operation of the mechanical governor, a detection device for detecting the working state parameters of the mechanical governor, and a dashboard for displaying the operating state parameters of the mechanical governor; the electronic speed regulation test bench includes an electronic governor and a support frame for supporting the electronic governor; the intelligent calibration device is installed on the support frame and includes an upper computer device and a lower computer device; the upper computer device is used to simulate and output the working mode of the diesel generator and provide test working parameters for the electronic governor and the mechanical governor based on the working mode of the diesel generator; the lower computer device is respectively connected to the upper computer device, the electronic governor, the mechanical speed control box, and the detection device, and is used to send the corresponding test working parameters to the electronic governor and the mechanical governor, and collect the working state parameters of the electronic governor and the working state parameters of the mechanical governor in real time to the upper computer device, and the upper computer device displays and analyzes the working state parameters of the electronic governor and the working state parameters of the mechanical governor to calibrate the electronic governor and the mechanical governor.

[0007] In an implementation manner of the first aspect, a servo motor, an oil pump motor, a filter, a valve group, an oil tank oil circuit, a lubrication pipeline, a heating device, a temperature sensor, and a voltage regulation system are installed in the mechanical speed regulation transmission box; the detection device includes a speed sensor and an angle sensor installed on the mechanical governor; the dashboard includes various combinations of a DC power supply display meter, a tachometer, a thermometer, and an oil pressure gauge.

[0008] In an implementation manner of the first aspect, the electronic speed regulation test bench further includes: an auxiliary analysis terminal connected to the electronic governor, and the auxiliary analysis terminal is installed with a preset test software for reading and writing the set parameters in the electronic governor and recording the change of the working parameters of the electronic governor.

[0009] In an implementation manner of the first aspect, the host device is configured with: a diesel generator simulation module, an electronic governor simulation test module, and a mechanical governor simulation test module; the diesel generator simulation module is used to simulate and output the working mode of the diesel generator, and input test working parameters to the electronic governor and the mechanical governor based on the working mode of the diesel generator and the slave device; the electronic governor simulation test module collects in real time, through the slave device, the working state parameters generated by the electronic governor according to the test working parameters, and displays and analyzes the working state parameters of the electronic governor; the mechanical governor simulation test module collects in real time, through the slave device, the working state parameters of the mechanical governor, and displays and analyzes the working state parameters of the mechanical governor.

[0010] In an implementation manner of the first aspect, the diesel generator simulation module includes: a mode control unit that generates a test signal or a simulation signal corresponding to the working mode under the corresponding working mode based on the working mode of the diesel generator; the test signal and the simulation signal respectively include a parameter command signal and a synchronization signal; the working mode of the diesel generator includes one or more combinations of the following: start / stop, trip / disconnect, normal / emergency start mode, idle start / full speed start mode, speed droop speed regulation mode / constant speed regulation mode, speed increase, speed decrease, two independent analog speeds, and mechanical governor speed; a signal output control unit that outputs the parameter command signal to the corresponding electronic governor or mechanical governor through the slave module, and outputs the synchronization signal to the slave module for the slave module to control the output of the parameter command signal; wherein, the parameter command signals are sent one by one according to the message queue, and the synchronization signals are sent repeatedly at equal intervals.

[0011] In an implementation manner of the first aspect, the diesel generator simulation module further includes: a mode recording unit for recording the change of the working mode of the diesel generator; a mode change display unit that generates and displays in real time a change curve of the working mode of the diesel generator according to the recorded change of the working mode of the diesel generator.

[0012] In an implementation manner of the first aspect, the host device is further configured with: a parameter configuration module for configuring the acquisition variables to be acquired from the electronic governor and the mechanical governor; wherein, the acquisition variables are configured as display variables and non-display variables.

[0013] In an implementation manner of the first aspect, the electronic governor simulation test module includes: a status parameter display unit, configured to generate a continuous change curve of the operating status parameters of the electronic governor based on the change of the operating status parameters of the electronic governor corresponding to the display variables; the operating status parameters of the electronic governor include digital quantity change, operating current display, actual speed measurement, speed set value, number of failures of the speed probe, and number of failures of the watchdog; a channel waveform unit, configured to record and display waveforms of each channel of the electronic governor; an electronic governor fault analysis unit, configured to analyze and obtain the fault status of the electronic governor based on the operating status parameters of the electronic governor.

[0014] In an implementation manner of the first aspect, the mechanical governor simulation test module includes: an operating status acquisition and display unit, configured to acquire and display the operating status of the mechanical governor during different speeds, acceleration, and deceleration processes; a status change acquisition and display unit, configured to acquire and display the change of the output angle of the mechanical governor and the status change of the throttle rack; a curve recording unit, configured to record any one or a combination of the speed curve, current curve, and rack curve of the mechanical governor according to the operating status and status change; a mechanical governor fault analysis unit, configured to determine whether the mechanical governor has jitter or stall according to the operating status and status change.

[0015] In a second aspect, an embodiment of the present application provides an integrated intelligent calibration method for a diesel generator speed regulation system, which is applied to the integrated intelligent calibration system of the diesel generator speed regulation system as described above, and includes: simulating and outputting the operating mode of the diesel generator, and providing test operating parameters for the electronic governor and the mechanical governor based on the operating mode of the diesel generator; real-time collecting the operating status parameters generated by the electronic governor according to the test operating parameters, displaying and analyzing the operating status parameters of the electronic governor, and real-time collecting the operating status parameters generated by the mechanical governor according to the test operating parameters, and displaying and analyzing the operating status parameters of the mechanical governor.

[0016] 1. The integrated intelligent calibration system of the diesel generator speed regulation system provided by the present application can simultaneously test and evaluate the operating status of the mechanical governor and the electronic governor of the diesel generator speed regulation system, realizes the off-line detection and calibration analysis of the diesel generator speed regulation system, can comprehensively monitor the operating status of the diesel generator speed regulation system, reduces the fault judgment and decision-making time, reduces the unplanned unavailable time of the nuclear power emergency generator set, and increases the safety and economic benefits of the nuclear power plant.

[0017] 2. The integrated intelligent calibration system for the diesel generator speed control system provided by this application can significantly reduce the return factory test and calibration costs of mechanical governors and electronic governors, ensuring the reliability and availability of the speed control system.

[0018] 3. This application can be used to train operators. It can not only detect the diesel generator speed control system but also achieve the purpose of technical training. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It shows the structural schematic diagram of the integrated intelligent calibration system for the diesel generator speed control system according to an embodiment of this application.

[0020] Figure 2 It shows the overall structural schematic diagram of the integrated intelligent calibration system for the diesel generator speed control system according to an embodiment of this application.

[0021] Figure 3 It shows the schematic diagram of the principle of auxiliary analysis in the integrated intelligent calibration system for the diesel generator speed control system according to an embodiment of this application.

[0022] Figure 4 It shows the schematic diagram of the principle of the upper computer device in the integrated intelligent calibration system for the diesel generator speed control system according to an embodiment of this application.

[0023] Figure 5 It shows the schematic diagram of the principle of the diesel generator simulation module in the integrated intelligent calibration system for the diesel generator speed control system according to an embodiment of this application.

[0024] Figure 6 It shows the schematic diagram of the working principle of the upper computer device in the integrated intelligent calibration system for the diesel generator speed control system according to an embodiment of this application.

[0025] Figure 7 It shows the schematic structural diagram of the principle of the electronic governor simulation test module in the integrated intelligent calibration system for the diesel generator speed control system according to an embodiment of this application.

[0026] Figure 8 It shows the schematic structural diagram of the principle of the mechanical governor simulation test module in the integrated intelligent calibration system for the diesel generator speed control system according to an embodiment of this application.

[0027] Figure 9 It shows the schematic diagram of the working principle of the intelligent calibration device in the integrated intelligent calibration system for the diesel generator speed control system according to an embodiment of this application.

[0028] Figure 10Schematic diagram showing the process of the intelligent calibration electronic governor in the integrated intelligent calibration system of the diesel generator speed regulation system according to an embodiment of the present application.

[0029] Figure 11 Schematic diagram showing the process of monitoring the electronic governor in the integrated intelligent calibration system of the diesel generator speed regulation system according to an embodiment of the present application.

[0030] Figure 12 Schematic diagram showing the process of fault monitoring and analysis of the electronic governor in the integrated intelligent calibration system of the diesel generator speed regulation system according to an embodiment of the present application.

[0031] Figure 13 Schematic diagram showing the flow of the integrated intelligent calibration method for the diesel generator speed regulation system according to an embodiment of the present application.

[0032] Figure 14 Schematic diagram showing the structure of an electronic device according to an embodiment of the present application.

[0033] Through the above-mentioned drawings, specific embodiments of the present application have been shown, and there will be more detailed descriptions hereinafter. These drawings and text descriptions are not intended to limit the scope of the concept of the present application in any way, but to illustrate the concept of the present application to those skilled in the art by referring to specific embodiments. Specific Embodiments

[0034] The following uses specific specific examples to illustrate the implementation manners of the present application. Those skilled in the art can easily understand other advantages and effects of the present application from the content disclosed in this specification. The present application can also be implemented or applied through other different specific implementation manners. Various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present application. It should be noted that, without conflict, the following embodiments and the features in the embodiments can be combined with each other.

[0035] This embodiment provides an integrated intelligent calibration system and method for a diesel generator speed regulation system, which is used for offline test and calibration of the diesel generator speed regulation system.

[0036] The following will elaborate in detail on the principle and implementation manner of an integrated intelligent calibration system and method for a diesel generator speed regulation system in this embodiment, so that those skilled in the art can understand an integrated intelligent calibration system and method for a diesel generator speed regulation system in this embodiment without creative labor.

[0037] This embodiment provides an integrated intelligent calibration system for a diesel generator speed regulation system. Figure 1 Schematic diagram showing the structural principle of the integrated intelligent calibration system of the diesel generator speed regulation system according to an embodiment of the present application. As Figure 1As shown in the figure, the integrated intelligent calibration system 100 of the diesel generator speed control system in this embodiment includes: a mechanical speed control test bench 110, an electronic speed control test bench 120, and an intelligent calibration device 130; the intelligent calibration device 130 provides test working parameters for the electronic governor 121 and the mechanical governor 111, and performs intelligent calibration on the electronic governor 121 and the mechanical governor 111. The integrated intelligent calibration system 100 of the diesel generator speed control system in this embodiment can simultaneously test and evaluate the operating states of the mechanical governor 111 and the electronic governor 121 of the diesel generator speed control system, realize off-line detection and calibration analysis of the diesel generator speed control system, can comprehensively monitor the operating state of the diesel generator speed control system, can significantly reduce the return factory test and calibration costs of the mechanical governor 111 and the electronic governor 121, ensure the reliability and availability of the speed control system, reduce the fault judgment and decision-making time, reduce the unplanned unavailable time of the nuclear power emergency generator set, and increase the safety and economic benefits of the nuclear power plant.

[0038] The following details the mechanical speed control test bench 110, the electronic speed control test bench 120, and the intelligent calibration device 130 of the integrated intelligent calibration system 100 of the diesel generator speed control system in this embodiment.

[0039] Specifically, in this embodiment, as Figure 1 shown, the mechanical speed control test bench 110 includes a mechanical governor 111, a mechanical speed control transmission box 112 that controls the operation of the mechanical governor 111, a detection device 113 that detects the working state parameters of the mechanical governor 111, and a dashboard 114 that displays the operating state parameters of the mechanical governor 111. Among them, the mechanical governor 111 is arranged on the mechanical speed control transmission box 112 through a base, the detection device 113 is installed on the mechanical governor 111, and the dashboard 114 is arranged on the base and behind the mechanical governor 111.

[0040] In one implementation of this embodiment, the mechanical governor 111 is disposed on the mechanical speed regulation transmission box 112 through a base and is controlled to operate through the mechanical speed regulation transmission box 112. Among them, a fixed flange device is provided on the base, and the mechanical governor 111 is fixed to the base through the fixed flange device. The mechanical speed regulation transmission box 112 is respectively connected to the lower computer device 132 and the electronic governor 121 and operates based on the test signals received from the lower computer device 132 and the electronic governor 121; the detection device 113 is installed on the mechanical governor 111, and the detection device 113 is connected to the lower computer device 132 and is used to transmit the detected operating parameters of the mechanical governor 111 to the lower computer device 132; the instrument panel 114 is disposed behind the mechanical governor 111 and is respectively connected to the mechanical governor 111 and the mechanical speed regulation transmission box 112 and is used to display the operating parameters of the mechanical governor 111.

[0041] Among them, as Figure 2 shown, in one implementation of this embodiment, a servo motor, an oil pump motor, a filter, a valve group, an oil tank oil circuit, a lubrication pipeline, a heating device, a temperature sensor, and a pressure regulating system are installed in the mechanical speed regulation transmission box 112.

[0042] Among them, the controller serves as the core control unit of the entire mechanical speed regulation transmission box and is responsible for coordinating the work of each component. According to the parameters received from the lower computer device 132 in the intelligent calibration device 130 and the input signals, it precisely controls the operating states of the mechanical governor and the servo motor to achieve precise adjustment of the transmission speed and direction; at the same time, it performs intelligent control on the heating device, the pressure regulating system, etc. to ensure that the transmission box can operate stably and efficiently under various working conditions. The controller is connected to the servo motor, the oil pump motor, the temperature sensor, etc. By receiving the temperature signal transmitted by the temperature sensor, the controller can regulate the heating device, the pressure regulating system, etc.; at the same time, it sends control commands to the servo motor to achieve control of the rotation speed and rotation direction of the transmission mechanism.

[0043] The transmission mechanism processes the rotational motion of the servo motor, such as decelerating and increasing torque, and then transmits it to the output shaft, thereby driving the mechanical governor. Specifically, one end of the transmission mechanism is connected to the servo motor, receives the power transmitted by the servo motor, and converts it into the rotational motion of the output shaft of the transmission box; the other end is connected to the output component of the transmission box and outputs the power to the mechanical governor.

[0044] The servo motor precisely controls the speed and rotation direction of the mechanical speed governor according to the instructions of the controller, providing appropriate power for the transmission mechanism. Its high-precision control ability enables the gearbox to meet the strict requirements for speed and rotation direction in different working scenarios, ensuring the operation accuracy and stability of the equipment. The servo motor is connected to the controller through a cable, receives the instructions of the controller, and precisely controls the speed and rotation direction of the mechanical speed governor according to the instructions. Its output shaft is connected to the input end of the transmission mechanism, providing power for the transmission mechanism.

[0045] The oil pump motor is connected to the oil pump and drives the oil pump to operate. The oil pump is connected to the fuel tank through a suction pipe, sucks the lubricating oil in the fuel tank, and transports the lubricating oil with a certain pressure to the lubrication pipeline in the gearbox through a discharge pipe. Among them, a filter is installed at the outlet of the oil pump or in the lubrication pipeline, its inlet is connected to the discharge pipe of the oil pump, and its outlet is connected to the lubrication pipeline. After the lubricating oil comes out of the oil pump, it first passes through the filter for filtration to remove impurities and particles in it, and then enters the lubrication pipeline.

[0046] The valve group can precisely control the flow rate and flow direction of the lubricating oil, adjust the appropriate amount of lubricating oil according to the needs of different parts, ensure that each part can be fully lubricated; at the same time, it plays a role in adjusting the pressure and maintaining the stability of the system in other oil circuits. Specifically, the valve group is distributed in the lubrication pipeline and other related oil circuits. In the lubrication pipeline, the valve group is used to control the flow rate and flow direction of the lubricating oil, adjust the appropriate amount of lubricating oil according to the needs of different parts, ensure that each part can be fully lubricated; in other oil circuits, such as the part related to the fuel tank oil circuit, the valve group can be used to control the ventilation between the fuel tank and the outside and the circulation of the oil fluid, etc., to ensure the pressure stability in the fuel tank and the normal circulation of the oil fluid.

[0047] The fuel tank oil circuit stores the lubricating oil, transports the lubricating oil to each part through the oil circuit, and recovers the used lubricating oil to realize the recycling of the lubricating oil. It can also play a role in heat dissipation and sedimentation of impurities, which is beneficial to maintaining the performance of the lubricating oil and the normal operation of the gearbox. Specifically, the fuel tank oil circuit includes multiple return pipes, and the fuel tank is connected to each lubrication part of the gearbox through the return pipes to form a closed oil circuit circulation system. The lubricating oil used after passing through each lubrication part returns to the fuel tank through the return pipe, and after sedimentation, heat dissipation and other treatments in the fuel tank, it is pumped again by the oil pump for recycling.

[0048] The lubrication pipeline accurately delivers the lubricating oil after filtration and regulation to each key part inside the transmission case, such as gears, bearings, etc. It reduces frictional losses, lowers the temperature of components, prevents component overheating and damage, ensures the stable operation of the transmission case, and improves its working efficiency and service life. Starting from the oil pump driven by the oil pump motor, after passing through the filter, it branches to each lubrication-required part inside the transmission case, such as the gear meshing position, bearings, etc. The lubrication pipeline is provided with different branches and valves of the lubrication pipeline according to different lubrication requirements to ensure that each part can obtain an appropriate and stable supply of lubricating oil.

[0049] The heating device is installed inside the oil tank or at a position close to the oil tank and is connected to the oil tank through a pipeline. When the ambient temperature is relatively low, the heating device starts to work, heats the lubricating oil inside the oil tank, so that the lubricating oil reaches an appropriate working viscosity, and ensures that the transmission case can also operate normally in a low-temperature environment.

[0050] The temperature sensor is installed inside the oil tank or at key parts (such as positions close to important transmission components), and its probe is exposed to the environment of the lubricating oil or inside the transmission case, and is used to monitor the temperature of the lubricating oil or the temperature change inside the transmission case in real time. The temperature sensor transmits the detected temperature signal to the controller.

[0051] The pressure regulating system works in coordination with the oil pump motor, the valve group, and the entire lubrication pipeline system. By regulating and controlling the pressure at the oil pump outlet or in the lubrication pipeline, it ensures that the lubricating oil can maintain a stable pressure supply under different working conditions and meets the requirements of each lubrication part.

[0052] The internal structure configuration of the mechanical speed regulation transmission case 112 in this embodiment can effectively establish the signal transmission between the mechanical speed governor 111 and the lower computer device 132 in the intelligent calibration device 130 and the offline control of the mechanical speed governor 111.

[0053] Among them, universal wheels are installed at the bottom of the mechanical speed regulation transmission case 112. The mechanical speed regulation transmission case 112 equipped with universal wheels can be easily moved on the ground without consuming a large amount of manpower and material resources for handling, so as to quickly adapt to the needs of new test scenarios. Moreover, during the installation process of the mechanical speed regulation test bench 110, the electronic speed regulation test bench 120, and the intelligent calibration device 130, the universal wheels can make the mechanical speed regulation test bench 110 rotate flexibly in the horizontal direction, facilitating the alignment installation with the electronic speed regulation test bench 120 and the intelligent calibration device 130 to make the connection smoother.

[0054] Since mechanical speed control gearboxes usually have a certain weight, especially some large and heavy-duty ones. If the mechanical speed control gearbox is directly placed on the ground, its weight will act concentratedly on a relatively small area, which may cause a large pressure on the ground and lead to ground damage. The casters can disperse the weight of the gearbox onto multiple wheels, reducing the pressure borne by the ground per unit area. For example, on the cement floor of some factories, if a heavy mechanical speed control gearbox is placed for a long time, it may cause cracks or depressions on the ground. After using casters, each wheel only bears a part of the weight, greatly reducing the burden on the ground and extending the service life of the ground.

[0055] In addition, in some debugging working environments, there may be vibration sources on the ground, such as the operation of large machine tools and the passing of transport vehicles. These vibrations will be transmitted to the mechanical speed control gearbox through the ground, having a certain impact on the internal components of the mechanical speed control gearbox. The casters have a certain shock-absorbing ability, which can absorb and buffer part of the vibration energy, reducing the impact of the vibration on the bottom of the mechanical speed control gearbox.

[0056] In this embodiment, an exemplary preferred working parameter of the mechanical speed control gearbox 112 is as follows: operating voltage: 220VAC, 50Hz; output power: 3.85KW; test speed range: 0 - 2000 RPM; speed measurement accuracy: ±1 RPM; oil pressure measurement range and accuracy: 0 - 600 PSI, 1 PSI; temperature measurement range and accuracy: 0 - 120 °C, 1 °C.

[0057] In one implementation of this embodiment, the detection device 113 includes a speed sensor and an angle sensor installed on the mechanical speed governor 111. Among them, the throttle adjustment output shaft of the mechanical speed governor 111 is exposed on the outer wall, the angle sensor is installed on the throttle adjustment output shaft exposed on the outer wall of the mechanical speed governor 111, and the speed sensor is installed at the corresponding part of the inner wall of the mechanical speed control gearbox 112 and the drive shaft speed measurement cam. The speed sensor is fixed on the inner wall of the mechanical speed control gearbox 112 and can align the probe of the speed sensor with the speed measurement cam to ensure that the speed of the cam can be accurately measured.

[0058] Among them, the speed measurement sensor is, but not limited to, an electromagnetic induction type speed measurement sensor, an optoelectronic speed measurement sensor, or a Hall type speed measurement sensor. In this embodiment, the electromagnetic induction type speed measurement sensor is taken as an example for illustration. When the speed measurement cam of the drive shaft rotates, the teeth or protrusions on the cam will sequentially pass through the probe of the sensor. The probe is usually a coil structure. Under the action of the magnetic field, the gap between the teeth or protrusions of the cam and the probe will change, resulting in a change in the magnetic resistance of the magnetic circuit. According to the principle of electromagnetic induction, the change in magnetic resistance will generate an induced electromotive force in the coil, and the magnitude of the induced electromotive force is proportional to the rotational speed of the cam. By measuring the magnitude and frequency of this induced electromotive force, the rotational speed of the speed measurement cam of the drive shaft can be calculated.

[0059] In one implementation manner of this embodiment, the instrument panel 114 includes a DC power display meter, a tachometer, a temperature gauge, an oil pressure gauge, and an indicator light. The instrument panel 114 is vertically installed on the mechanical speed regulation transmission box 112, and the width of the instrument panel 114 matches the width of the mechanical speed regulation transmission box 112.

[0060] Among them, in this embodiment, the actuator of the mechanical speed governor 111 is connected to the electronic speed governor 121 to obtain the working current from the electronic speed governor 121. That is to say, the electronic speed governor 121 is connected to the actuator of the mechanical speed governor 111 to provide current for the actuator of the mechanical speed governor 111.

[0061] Specifically, in this embodiment, the electronic speed regulation test bench 120 includes an electronic speed governor 121 and a support frame 122 for supporting the electronic speed governor 121. Among them, preferably, universal wheels are installed at the bottom of the support frame 122.

[0062] As Figure 3 shown, in one implementation manner of this embodiment, the electronic speed regulation test bench 120 further includes: an auxiliary analysis terminal 123 connected to the electronic speed governor 121. The auxiliary analysis terminal 123 is installed with preset test software for reading and writing the set parameters in the electronic speed governor 121 and recording the change of the working parameters of the electronic speed governor 121.

[0063] For example, the auxiliary analysis terminal 123 is configured with a diesel generator electronic governor 121 interface and parameter management LEEC tool software. The LEEC tool software is, for example, a special tool software of the original manufacturer. The LEEC software is installed on an IPC or a laptop computer and is connected to the electronic governor 121 through an RS232 interface, enabling reading and writing of the set parameters of the electronic governor 121 (black box) and recording of the changes in the working parameters of the electronic governor. As the original factory test tool software, the LEEC tool software can assist and verify the test results of testing the electronic governor 121 through the intelligent calibration device 130.

[0064] Specifically, in this embodiment, the intelligent calibration device 130 is installed on the support frame 122 and is used for intelligently calibrating the electronic governor 121 and the mechanical governor 111. The intelligent calibration device 130 includes an upper computer device 131 and a lower computer device 132 connected to the upper computer, the electronic governor 121, the mechanical speed regulation gearbox 112, and the detection device 113.

[0065] Among them, the upper computer device 131 is used to simulate and output the working mode of the diesel generator and provide test working parameters for the electronic governor 121 and the mechanical governor 111 based on the working mode of the diesel generator. The lower computer device 132 is respectively connected to the upper computer device 131, the electronic governor 121, the mechanical speed regulation gearbox 112, and the detection device 113, and is used to send the corresponding test working parameters to the electronic governor 121 and the mechanical governor 111, and collect the working state parameters of the electronic governor 121 and the working state parameters of the mechanical governor 111 in real time to the upper computer device 131. The upper computer device 131 displays and analyzes the working state parameters of the electronic governor 121 and the working state parameters of the mechanical governor 111 to calibrate the electronic governor 121 and the mechanical governor 111.

[0066] In an implementation manner of this embodiment, the slave device 132 is used to connect to the electronic governor 121. The slave device 132 includes an input / output unit and a signal acquisition unit. The input / output unit is used to transmit the command signal sent by the diesel generator simulation module to the electronic governor 121. The signal acquisition unit is used to acquire the control signal generated by the circuit to be measured of the electronic governor 121 based on the command signal. The input / output unit is further used to transmit the control signal to the simulation test module of the electronic governor 121 and the simulation test module of the mechanical governor 111. The simulation test module of the electronic governor 121 and the simulation test module of the mechanical governor 111 generate monitoring information based on the control signal, and display and analyze the working state parameters of the electronic governor 121 and the working state parameters of the mechanical governor 111, so as to calibrate the electronic governor 121 and the mechanical governor 111.

[0067] In this embodiment, specifically, a PLC is used as the slave device 132 to complete functions such as sampling of the original electrical signals of the diesel generator governor, storage unit allocation, A / D conversion, and signal filtering. The data communication is mainly in the Modbus and TCP / IP modes.

[0068] In this embodiment, the PLC of the slave device 132 selects instruments and power modules with excellent performance, uses terminal connectors and wires with good conductivity, and reasonably distributes the electrical components in the main control box. The whole machine is stable and has good insulation, so as to significantly improve the reliability and anti-interference ability of the operation of the slave device 132. When subjected to any electrical operations, lightning strikes, static electricity, radio transceivers and other electromagnetic interferences on site, there will be no false adjustment, misadjustment, false operation, refusal to operate and other situations.

[0069] In this embodiment, the parameters of the PLC of the slave device 132 are as follows: 1) Main I / O interfaces: 4xUSB2.0, 2xDB-9COM1&COM2, RS-232 / 422 / 485, 2xDB-9COM3&COM4, RS-232, 1x one-key restore system button; Storage: 1xmSATA / 1xSATA; Expansion slot: Mini-PCIEx1 on-board SIM card slot; Supported systems: Windows10 32 / 64-bit; 15-inch TFT liquid crystal display screen; Support touch operation, resolution: 1024*768; Supported interfaces: RS232, RJ45; Internal storage medium: 128GB SSD; Intel Core I5 series processor, 8GB memory; Material: aluminum magnesium alloy; Installation method: VESA100 / panel installation.

[0070] In this embodiment, the host device 131 includes an industrial computer, a touch screen disposed in front of the industrial computer, a plurality of operation buttons or / and operation knobs disposed next to the touch screen for controlling the electronic speed regulator 121 and the mechanical speed regulator 111 to perform intelligent verification, and a plurality of plug ports disposed at the back of the industrial computer. The plurality of plug ports include a plurality of VGA ports, USB ports, network interfaces, printer interfaces, and waveform recorder interfaces.

[0071] That is, in this embodiment, the host computer device 131 uses a touch screen LCD as a human-machine interface window, touch screen input and output control, a hot-swappable mobile storage device interface is reserved, and a printer and a waveform recorder are expandable peripherals.

[0072] The industrial computer of the host device 131 adopts an embedded industrial controller IPC, which can realize data function combination, higher cycle operation speed, storage and graphic display functions. For example, the industrial computer adopts an X86 high-order CPU based on the IPC architecture, which has low CPU power consumption, low heat generation, and strong computing and graphics processing capabilities. The main control unit of the industrial computer adopts an aluminum-magnesium alloy shell, which has fast heat dissipation, dustproof and shockproof, and a sturdy shell.

[0073] like Figure 4 As shown, in one implementation of this embodiment, the host computer device 131 is configured with: a diesel generator simulation module 1311, an electronic speed governor simulation test module 1312 and a mechanical speed governor simulation test module 1313.

[0074] Among them, in one implementation of this embodiment, the host device 131 is configured with operation mode protection, and data can be stored and retrieved during the test process in any mode. When the software platform of the host device 131 is used normally, the installation and operation of third-party software are not allowed, and data is not allowed to be written to the OS system storage area. Only data operations can be performed on the test data storage area. The software upgrade of the host device 131 or the installation of third-party APP software can only be carried out under the authorization of the operator and the OS system is converted to debugging mode. Accidental failures of the OS system in the host device 131 are eliminated, the life of the storage medium is extended, and storage space resources are saved.

[0075] Specifically, in one implementation of this embodiment, Figure 5 and Figure 6As shown, the diesel generator simulation module 1311 is used to simulate and output the operating modes of the diesel generator, and based on the operating modes of the diesel generator and the lower computer device 132, input test operating parameters to the electronic governor 121 and the mechanical governor 111; the electronic governor simulation test module 1312 collects in real time, through the lower computer device 132, the operating state parameters generated by the electronic governor 121 according to the test operating parameters, and displays and analyzes the operating state parameters of the electronic governor 121; the mechanical governor simulation test module 1313 collects in real time, through the lower computer device 132, the operating state parameters of the mechanical governor 111, and displays and analyzes the operating state parameters of the mechanical governor 111.

[0076] Specifically, in an implementation manner of this embodiment, the diesel generator simulation module 1311 includes: a mode control unit 1311a and a signal output control unit 1311b.

[0077] Among them, as Figure 5 shown, the mode control unit 1311a generates test signals or simulation signals corresponding to the operating modes based on the operating modes of the diesel generator; the test signals and the simulation signals respectively include parameter command signals and synchronization signals; the operating modes of the diesel generator include one or more combinations of the following: start / stop, trip / switch-on, normal / emergency start mode, idle start / full-speed start mode, speed drop governor mode / constant speed governor mode, speed increase, speed decrease, two independent simulated speeds, and the speed of the mechanical governor 111.

[0078] Among them, the signal output control unit 1311b outputs the parameter command signals to the corresponding electronic governor 121 or mechanical governor 111 through the lower computer device 132, and outputs the synchronization signals to the lower computer device 132 for the lower computer device 132 to control the output of the parameter command signals; among them, the parameter command signals are sent one by one according to the message queue, and the synchronization signals are sent repeatedly at equal intervals.

[0079] The signal output control unit 1311b generates parameter command signals specifically for each governor (including the electronic governor 121 and the mechanical governor 111) based on the system's preset operating logic, algorithms, and instruction information from the upper-level monitoring system. These signals cover key parameter information such as speed setpoints, acceleration limits, and operation mode switching commands. To ensure the orderliness and determinacy of signal transmission, all generated parameter command signals are arranged in an orderly manner in the message queue and wait to be sent sequentially. The lower-level device 132 establishes a stable data communication connection with the signal output control unit 1311b using a reliable communication protocol (such as industrial Ethernet, CAN bus, etc.). When the parameter command signals in the message queue need to be sent, the signal output control unit 1311b transmits the signals to the lower-level device 132 through the communication link. After receiving the signals, the lower-level device immediately analyzes and verifies them to ensure the integrity and accuracy of the signals. Subsequently, based on the pre-configured address mapping relationship or device identification information, the lower-level device 132 further forwards the parameter command signals to the corresponding electronic governor 121 or mechanical governor 111.

[0080] In an implementation manner of this embodiment, a high-precision clock module or time reference source is provided inside the signal output control unit 1311b, and based on this, a synchronization signal with a fixed time interval (such as 1 ms, 10 ms, etc., set according to system requirements) is generated. This synchronization signal serves as a global time reference standard for coordinating the operating rhythms of various devices in the entire system. Similar to the parameter command signals, the synchronization signal in this embodiment is sent from the signal output control unit 1311b to the lower-level device 132 through the same communication link. After receiving the synchronization signal, the lower-level device, on the one hand, forwards it to the connected governors (electronic governor 121 and mechanical governor 111), and on the other hand, calibrates the local timer using the time information carried by the synchronization signal. This calibration process ensures that the timing mechanisms inside each governor are consistent with the overall system time reference, so that they can respond to the parameter command signals at exactly the same moment and achieve synchronous operation. For example, the electronic governors and mechanical governors of each axis work together based on the synchronization signal to achieve complex spatial trajectory movements or precise position positioning.

[0081] In this embodiment, by sending parameter command signals one by one and combining with synchronization signals, it can ensure that each speed governor receives the corresponding control parameters at a predetermined accurate moment, so as to achieve high-precision adjustment of key operating parameters such as speed and torque. For example, in a precision CNC machine tool, when the electronic speed governor drives the spindle motor and the servo motor, it can achieve machining accuracy at the micron or even nanometer level according to the precise parameter command signals sent by the signal output control unit, meeting the high-precision machining requirements of complex parts. Moreover, the existence of the synchronization signal enables precise synchronous operation between multiple speed governors (whether electronic speed governors or mechanical speed governors). The signal output control unit 1311b can monitor the operating state information of each speed governor in real time (such as actual speed, current feedback, etc.). When the lower computer device 132 feeds back the operating data of the speed governor to the signal output control unit, the latter can adjust the subsequent parameter command signals in a timely manner according to these data to cope with possible load changes, interference and other factors, further enhancing the adaptive ability and stability of the system.

[0082] In an implementation manner of this embodiment, the diesel generator simulation module 1311 can display and record the continuous changes of all parameters of the diesel generator working mode and present them in the form of real-time curves. The diesel generator simulation module 1311 further includes: a mode recording unit and a mode change display unit; the mode recording unit is used to record the changes of the diesel generator working mode; the mode change display unit is used to generate and display the change curve of the diesel generator working mode in real time according to the recorded changes of the diesel generator working mode.

[0083] In this embodiment, the mode recording unit can collect various types of parameters during the operation of the diesel generator, including but not limited to speed, torque, power, fuel injection pressure, cylinder pressure, temperature, etc. It performs data collection at an extremely high frequency to ensure that every detail of the change of the diesel generator working mode can be captured. For example, the collection frequency of speed can reach several times per millisecond, so that even during the rapid acceleration or deceleration of the diesel generator, the continuous change of speed can be accurately recorded. The mode recording unit has a powerful data storage capacity and adopts efficient data compression and storage algorithms, which can store a large amount of mode data in limited storage space. It can store the data in time series for convenient subsequent query and analysis. At the same time, to ensure the security and integrity of the data, it also has data backup and recovery functions to prevent data loss due to unexpected situations.

[0084] Specifically, in this embodiment, the modal change display unit incorporates an advanced curve generation algorithm, which can quickly and accurately generate the change curve of the operating mode of the diesel generator according to the data provided by the modal recording unit. This algorithm should meet the requirements of data continuity, smoothness, and real-time performance. By interpolating and fitting the collected data, a clear and accurate curve is generated. For example, when plotting the rotational speed change curve, the spline curve interpolation algorithm is used to generate a smooth curve between adjacent collected data points, more realistically reflecting the change trend of the rotational speed. The modal change display unit can visually display the change curve of the operating mode of the diesel generator in real time. Users can operate the display interface through a touch screen or mouse, such as zooming in, zooming out, and panning the curve, etc., in order to observe the modal changes in a specific time period in more detail. At the same time, the display interface can also display the change curves of multiple parameters simultaneously, distinguished by different colors and line types, facilitating users to conduct comparative analysis.

[0085] In addition to real-time curve display, the modal change display unit also has rich interactive functions. Users can click on any point on the curve to obtain all the parameter values corresponding to that moment; they can also select a specific time period to view the statistical information on the changes in the diesel generator mode during that time period, such as maximum value, minimum value, average value, etc. In addition, users can set thresholds. When a certain parameter exceeds the threshold, the display unit will issue an alarm prompt to help users detect abnormal situations in a timely manner.

[0086] By continuously monitoring and recording all parameter changes in the operating mode of the diesel generator and generating corresponding curves, the modal change display unit can promptly detect abnormal situations during the operation of the diesel generator. For example, when there are abnormal fluctuations in the pressure of a certain cylinder, it may indicate problems with the fuel injector or seal of that cylinder. By comparing the parameter curves under normal operating conditions with the actual operating curves, the fault point can be quickly located, providing accurate fault information for maintenance personnel and facilitating timely maintenance to prevent the further expansion of the fault.

[0087] Based on a large amount of historical data and advanced data analysis algorithms, the modal change display unit can predict the future working state of the diesel generator. By analyzing the parameter change trends, potential faults can be predicted in advance, and warning information can be provided to operators. This enables maintenance work to shift from passive after-failure maintenance to proactive preventive maintenance, reducing the failure rate of the equipment and improving the reliability and availability of the diesel generator.

[0088] In addition, for teaching and training activities related to diesel generators, the modal change display unit provides an intuitive and vivid teaching tool. Through the modal change display unit, trainees can observe the working modal changes of diesel generators under different parameter settings and working conditions, thereby deepening their understanding of the working principles and performance characteristics of diesel generators. This interactive learning method can improve trainees' learning interest and learning effects, and cultivate more professional talents with practical abilities.

[0089] In one implementation of this embodiment, the electronic governor simulation test module 1312 manages the on-off and analog input parameters provided to the electronic governor 121 according to the requirements of the diesel generator simulation module 1311, and measures all parameters and provides them to the diesel generator simulation module 1311.

[0090] Specifically, in one implementation of this embodiment, the host device 131 is further configured with: a parameter configuration module, which manages the on-off and analog input parameters provided to the electronic governor 121. Specifically, the parameter configuration module configures the acquisition variables to be collected from the electronic governor 121 and the mechanical governor 111; among them, the acquisition variables are configured as display variables and non-display variables.

[0091] In one implementation of this embodiment, the electronic governor simulation test module 1312 can display and record the continuous changes of all parameters of the electronic governor 121 and present them in the form of real-time curves. Moreover, the electronic governor simulation test module 1312 can have functions such as historical monitoring information data playback and combined detailed analysis. The waveform data can be analyzed on-site and can also be captured and stored to achieve real-time display of joint debugging data and comparison with historical records.

[0092] In this embodiment, the electronic governor simulation test module 1312 supports playback from different perspectives. For example, it can view the changes of a specific parameter alone, or compare the changes of multiple related parameters simultaneously. For instance, the change curves of motor speed and current can be played back simultaneously to analyze their correlation and understand how the current change affects the speed. To facilitate users in observing data changes at different stages, the electronic governor simulation test module 1312 also provides a playback speed control function. Users can speed up or slow down the playback speed, and even pause at specific time nodes to conduct more detailed viewing and analysis of key parts. Moreover, in this embodiment, the electronic governor simulation test module 1312 allows users to select multiple parameters for combined analysis. For example, analyzing the combination of three parameters: motor speed, torque, and current can provide a more comprehensive understanding of the performance of the electronic governor under different load conditions. By observing the mutual relationships and change rules among these parameters, some potential problems or optimization points can be discovered. In addition, the electronic governor simulation test module 1312 also incorporates various refined analysis tools, such as a magnifying glass tool and a cursor measurement tool. The magnifying glass tool enables users to magnify a local area of the curve to more clearly view minute changes; the cursor measurement tool can add cursors at any position on the curve, and by measuring the horizontal distance (representing the time difference) and vertical distance (representing the difference in parameter values) between the cursors, relevant parameters such as acceleration and change rate can be calculated.

[0093] In this embodiment, the electronic governor simulation test module 1312 has real-time calculation and statistical functions. It can quickly process and analyze waveform data while collecting data, and calculate some key characteristic values, such as maximum value, minimum value, average value, peak-to-peak value, etc. These characteristic values can help users quickly understand whether the current working state of the electronic governor is normal and whether there are abnormal fluctuations.

[0094] In this embodiment, the electronic governor simulation test module 1312 also has a capture and storage function. The capture and storage function of waveform data enables users to save the current waveform data at any time for subsequent offline analysis and report generation. The captured pictures can clearly display the waveform shapes and numerical sizes of each parameter at that time, providing users with an intuitive recording method.

[0095] In this embodiment, the electronic governor simulation test module 1312 can quickly and accurately detect faults occurring during the operation of the electronic governor by continuously monitoring the continuous changes of all parameters of the electronic governor and combining historical monitoring information data playback and combined refinement analysis functions. For example, when the motor speed shows abnormal fluctuations, the playback function can be used to view the changes in speed and other relevant parameters before and after the fault occurs, and the refinement analysis tool is used to measure the change range and rate of key parameters, so as to judge the type and cause of the fault, such as whether the speed runaway is caused by abnormal PWM signals, etc.

[0096] In this embodiment, the combined refinement analysis function of the electronic governor simulation test module 1312 can help users further locate the fault point. By comprehensively analyzing multiple relevant parameters, the possible range of the fault can be narrowed down to determine whether it is caused by faults in internal circuit components of the electronic governor, software algorithm problems, external interference, or other factors. For example, if it is found that the current and speed both show abnormalities while the voltage is normal, then there may be problems with the motor or its drive circuit; if the duty cycle and frequency of the PWM signal are abnormal, then there may be faults in the control algorithm or signal generation circuit. In addition, by long-term collecting and analyzing the operation data of the electronic governor, the functions provided by the electronic governor simulation test module 1312 in this embodiment can be used to find performance bottlenecks and optimization spaces. For example, by observing the change curves of the motor speed and current under different load conditions and analyzing their energy consumption, the control strategy of the PWM signal can be adjusted accordingly, such as changing the size of the duty cycle or the level of the frequency, to reduce energy consumption and improve the operation efficiency of the motor. The real-time display function of the electronic governor simulation test module 1312 allows engineers to immediately see the parameter changes when adjusting the electronic governor, so as to verify the adjustment effect. For example, when the PID (Proportional-Integral-Derivative) control parameters are adjusted, it can be observed through the real-time curve whether the motor speed follows the set value more stably and whether the current is more stable, etc., so as to fine-tune the parameters in a timely manner to achieve the best performance optimization effect.

[0097] Specifically, as Figure 7 shown, the electronic governor simulation test module 1312 includes: a status parameter display unit 1312a, a channel waveform unit 1312b, and an electronic governor fault analysis unit 1312c.

[0098] Among them, the state parameter display unit 1312a is configured to generate a continuous change curve of the operating state parameters of the electronic governor 121 based on the change of the operating state parameters of the electronic governor 121 corresponding to the display variable; the operating state parameters of the electronic governor 121 include digital quantity change, operating current display, actual speed measurement, speed set value, number of speed probe failures, and number of watchdog failures. Among them, the state parameter display unit 1312a can identify the drive currents of different electronic governors 121 (0 - 200 mA, 0 - 1 A); the channel waveform unit 1312b is configured to record and display the waveforms of each channel of the electronic governor 121; the electronic governor fault analysis unit 1312c is configured to analyze and obtain the fault state of the electronic governor 121 based on the operating state parameters of the electronic governor 121.

[0099] In one implementation manner of this embodiment, the mechanical governor simulation test module 1313 can implement speed setting, oil pressure test, output angle test, etc. for the mechanical governor 111, and the speed of the motor can be adjusted within 0 - 2000 rpm. The mechanical governor simulation test module 1313 can display and record the continuous changes of all parameters of the mechanical governor 111 and present them in the form of real-time curves. Specifically, as Figure 8 shown, the mechanical governor simulation test module 1313 includes: an operating state acquisition and display unit 1313a, a state change acquisition and display unit 1313b, a curve recording unit 1313c, and a mechanical governor fault analysis unit 1313d.

[0100] Among them, the operating state acquisition and display unit 1313a acquires and displays the operating state of the mechanical governor 111 during different speeds, acceleration, and deceleration processes; the state change acquisition and display unit 1313b acquires and displays the change of the output angle of the mechanical governor 111 and the state change of the throttle rack; the curve recording unit 1313c is configured to record any one or a combination of the speed curve, current curve, and rack curve of the mechanical governor 111 according to the operating state and state change; the mechanical governor fault analysis unit 1313d is configured to determine whether the mechanical governor 111 has jitter or stall according to the operating state and state change.

[0101] In this embodiment, through the diesel generator simulation module 1311, the working parameters of each channel of the mechanical governor 111 to be measured can be configured, including the simulated speed and the set speed, etc. The throttle output current value of the actuator output by the electronic governor 121 to the mechanical governor 111, and the mechanical governor 111 adjusts the speed in response under the combined action of the comparison of the current value, the simulated speed and the set speed, so as to change the output angle of the output shaft of the mechanical governor 111 for throttle adjustment. The mechanical governor simulation test module 1313 records the continuously changing curve of the parameters of this adjustment state.

[0102] In this embodiment, the diesel generator simulation module 1311 outputs a continuously changing speed signal to the mechanical governor 111, driving the mechanical governor 111 to operate within a specific speed range, so that the mechanical governor simulation test module 1313 can not only obtain the operating state of the mechanical governor 111 during different speeds, acceleration and deceleration processes, whether there are jitter or stall phenomena; at the same time, it can obtain the change of the output angle and the state change of the throttle rack, and can record the speed curve, current curve, and rack curve, and then measure the working state of the mechanical governor 111.

[0103] Specifically, the control and monitoring of the mechanical governor 111 by the diesel generator simulation module 1311 include:

[0104] 1) Speed signal output and governor drive

[0105] 1-1) Speed signal generation: The diesel generator simulation module 1311 has a highly accurate signal generation ability and can output continuous and stable speed signals to the mechanical governor 111. These speed signals are not simple fixed values, but show delicate changes within a certain range, and can accurately simulate the speed fluctuations of diesel generators under various actual working conditions. For example, during the simulation of the diesel generator startup process, the speed signal will start from a lower value and gradually rise along a specific acceleration curve until it reaches the stable operating speed range. This continuously changing speed signal can provide comprehensive input conditions for subsequent tests of the mechanical governor under different speed conditions.

[0106] 1-2) Governor operation control: Through the continuously varying speed signal described above, the mechanical governor 111 is accurately driven to operate within a specific speed range. This specific speed range is set according to the actual working requirements and performance characteristics of the diesel generator, and can cover all key intervals from idle speed to rated speed. During this process, the mechanical governor can respond in real time to the input speed signal and adjust its output through its internal adjustment mechanisms, such as changes in the centrifugal force of the centrifugal flyweights, changes in spring force, etc., to maintain the stable operation of the diesel generator within the given speed range. This enables the test process to comprehensively cover various dynamic performances of the governor under normal working conditions.

[0107] 2) Operating state monitoring

[0108] 2-1) Jitter and stall detection

[0109] Jitter phenomenon monitoring: During the operation of the mechanical governor 111, the diesel generator simulation module 1311 will continuously monitor whether there is a jitter phenomenon in the governor. Jitter usually manifests as small, rapid, and irregular fluctuations in the output speed of the governor or related components. Such fluctuations may cause the unstable operation of the diesel generator, affecting its performance and service life. By collecting and analyzing the speed signal with high precision and synchronously comparing it with the data of other relevant sensors, the key parameters such as the occurrence time, jitter amplitude, and jitter frequency of the jitter can be accurately identified. For example, when the load of the diesel generator suddenly changes, if the governor cannot adjust in a timely and effective manner, it may show obvious jitter in the speed signal, and all of this will be keenly captured by the monitoring system.

[0110] Stall phenomenon warning: Stall refers to the phenomenon that the mechanical governor loses its normal control ability over the speed of the diesel generator under certain circumstances, resulting in a sharp drop in speed or inability to maintain within the normal range. This may be caused by factors such as internal component failures of the mechanical governor, sensor failures, or external interferences. The diesel generator simulation module 1311 will continuously monitor the change trend of the speed signal. Once it detects that the speed shows an abnormal rapid drop and the governor cannot compensate through normal adjustment, it will immediately trigger the stall warning mechanism. At the same time, it will also record the relevant data before the stall occurs for subsequent analysis and diagnosis of the cause of the failure.

[0111] 2-2) Output angle and throttle rack state change

[0112] Output Angle Measurement: The output angle of the mechanical governor is one of the important parameters reflecting its working state. During the test, the output angle of the governor is measured and recorded in real time by a dedicated angle sensor. As the speed of the diesel generator changes and the governor adjusts, the output angle will change accordingly. For example, when the diesel generator accelerates, the output angle of the governor may increase to increase the fuel supply and thus improve the output power of the diesel generator; conversely, when decelerating, the output angle will decrease. By accurately monitoring the change of the output angle in this embodiment, the control strategy and effect of the mechanical governor on the fuel supply system under different working conditions can be deeply understood.

[0113] Throttle Rack State Monitoring: The throttle rack is a key link connecting the governor and the fuel supply mechanism, and its state change directly affects the operating performance of the diesel generator. During the test, the position, moving speed and force condition of the throttle rack are monitored in real time. When the mechanical governor drives the throttle rack to act, its position will change, and the moving speed of the throttle rack will also be different under different speed and load conditions. At the same time, by monitoring the force on the throttle rack, it can be judged whether there are problems such as jamming and abnormal resistance during its movement. These information are of great significance for evaluating the working state of the governor and the performance of the entire fuel supply system.

[0114] 3) Data Recording and Analysis

[0115] 3-1) Speed Curve Recording: During the entire test process, the diesel generator simulation module 1311 will collect and record the output speed signal of the mechanical governor 111 in real time to generate a detailed speed curve. This speed curve can not only intuitively show the speed change of the governor at different time points, but also reflect the operating stability and dynamic response characteristics of the diesel generator under various working conditions. By analyzing the speed curve, key performance indicators such as the average speed, speed fluctuation rate, acceleration time and deceleration time of the diesel generator can be calculated, so as to comprehensively evaluate the performance of the diesel generator and the governor.

[0116] 3-2) Current Curve Recording: In addition to the speed curve, this embodiment will also record the current curve related to the mechanical governor. The current curve can reflect the electrical characteristics of the governor during operation, such as the current consumption of the motor and the change of electromagnetic torque. By analyzing the current curve, the energy consumption of the governor under different speed and load conditions can be understood, as well as whether there are problems such as overload or abnormal current consumption. At the same time, by comparing and analyzing the speed curve and the current curve, the working efficiency and performance optimization space of the governor can be further revealed.

[0117] 3-3) Rack Curve Recording: In this embodiment, the position-time curve of the throttle rack, i.e., the rack curve, is recorded. The rack curve can clearly show the movement trajectory and variation law of the throttle rack under different working conditions. By analyzing the rack curve, the corresponding relationship between the throttle rack and the governor output, as well as the response characteristics under different operating conditions, can be studied. For example, according to the slope of the rack curve, the moving speed of the throttle rack can be judged, and then the adjustment speed of the governor for the fuel supply amount can be inferred; by observing the shape and fluctuation of the rack curve, the smoothness and accuracy of the throttle rack movement can be evaluated.

[0118] The integrated intelligent calibration system 100 provided by the embodiment of the present application for a diesel generator speed regulation system provides a simulation test that is almost completely close to the actual on-site environment. The test system simulates the voltage and current amplitudes provided to the corresponding channels of the governor when the diesel generator is operating, compared with the voltage and current amplitudes given during the operation of the diesel generator.

[0119] In this embodiment, as Figure 9 shown, when the host computer device 131 is running, it can perform monitoring and offline simulation tests. It can also only evaluate and analyze the monitoring and offline simulation tests. Among them, when the electronic governor simulation test module 1312 and the mechanical governor simulation test module 1313 only display the collected data and do not perform further processing and analysis on the collected data, the electronic governor 121 and the mechanical governor 111 can be monitored only through the diesel generator simulation module 1311. The host computer device 131 generates monitoring information according to the received electrical signal and then displays the monitoring information in real time. Professional technicians can analyze and judge the actual operating state of the diesel generator by observing the monitoring information, and then judge whether the adjustment function of the electronic governor 121 is abnormal. When using the diesel generator governor monitoring function, start the diesel generator electronic governor 121 test software, display the LOGO interface, click to enter the main interface, establish communication between the host computer and the lower computer signal transmission module, and the operation interface of the diesel generator simulation module will appear. There are various sub-modules of the above-mentioned diesel generator simulation module 1311 on the operation interface, and various operations can be performed. By obtaining the operation permission, various calibration data and the preset values of the simulated speed and acceleration can be automatically changed according to the test mode.

[0120] In this embodiment, when performing an offline simulation test on the electronic governor 121, the input / output unit of the lower computer device 132 is connected to the electronic governor 121 through a cable for transmitting command signals. Then, multiple probes are respectively connected to the corresponding lines of the electronic governor 121 for collecting control signals. The diesel generator simulation module 1311 of the upper computer device 131 sends a test command to the input / output unit through the operation interface. The test command includes a command signal and a synchronization signal. Then, the input / output unit transmits the command signal to the electronic governor 121. To ensure the response timing of the PLC of the lower computer device 132, the command signals are sent one by one according to the queue organization, and the synchronization signals are sent repeatedly at equal intervals. When the PLC does not receive the synchronization signal, all outputs are prohibited. After receiving the command signal, the electronic governor 121 generates a control signal based on the command signal. The control signal is mainly reflected by the current. The change value of the current on the test line is collected by the probe and transmitted to the electronic governor simulation test module 1312 through the input / output unit. The PLC organizes data periodically and uploads it in batches to the electronic governor simulation test module 1312. The electronic governor simulation test module 1312 performs data decompression, display, and storage. The channel for signal collection uses the TCP / IP protocol. After the upper computer device 131 starts communication, it starts listening for the connection request of the PLC. After establishing a connection, it starts listening for data packets. The data packets carry timestamps to ensure the accurate acquisition time. If a network interruption occurs, after the network resumes, the pre-set automatic recovery mechanism of the communication channel can automatically reconstruct the two communication channels to ensure the continuity and integrity of data collection.

[0121] The electronic governor simulation test module 1312 of the upper computer device 131 continuously records the continuous change process of all adjustment parameters of the online working state of the electronic governor 121, and also records the possible fault state data of the electronic governor 121. That is, it can be analyzed on-site, and snapshots can also be taken. It continuously records the working state parameters of all channels of the electronic governor 121 for a long time, and performs digital processing such as data playback, combination, and superposition of all channel data, fully realizing the scenario reproduction. The electronic governor simulation test module 1312 stores the command signals sent by the diesel generator simulation module in real time, that is, records the operation behavior. By recording the operation behavior and the results (monitoring information) caused by the operation behavior. To facilitate technicians to intuitively compare the data waveform image information, the electronic governor simulation test module 1312 of this embodiment has built-in data analysis tools, so as to better analyze the cause of the failure of the electronic governor 121 and quickly perform fault diagnosis and analysis on the electronic governor 121.

[0122] In this embodiment, the intelligent verification device 130 mainly monitors and simulates test data including:

[0123] 1) Changes in the working parameters of each channel of the electronic governor 121: changes in digital quantities, display of working current, measurement of actual speed, speed set value, number of revolver probe faults, number of watchdog faults, etc.;

[0124] 2) Changes in the measured set state parameters: RUN, STOP states, in-network and off-network states, idle speed, full-speed start mode, speed reduction and regulation mode, constant-speed regulation mode, speed reduction, speed increase operation states, governor fault reset, simulated speed changes, and other parameters.

[0125] Based on the software operation principle of the intelligent verification device 130 of this embodiment, the intelligent verification device 130 of this embodiment has an analog test mode, a monitoring and measurement working mode, and a fault diagnosis working mode.

[0126] As Figure 10 shown, in the analog test mode, the system displays a test function panel and various operations can be performed. By obtaining operation permissions, various calibration data and preset values of simulated speed and acceleration can be automatically changed according to the test mode.

[0127] As Figure 11 shown, in the monitoring and measurement working mode, the intelligent verification device 130 continuously records the states of current, voltage, speed, ECC, etc. The analog test operation function is disabled, and the recording action starts and stops collection through the recording menu. The scrolling of the waveform recording window can also be paused.

[0128] As Figure 12 shown, in the fault diagnosis working mode, various real-time data and historical working data are analyzed. To facilitate the user to intuitively compare the data waveforms, the intelligent verification device 130 pre-sets at least one analysis tool. Various real-time data and historical working data are recorded with characteristic values such as equipment model and governor number, and the start, end, and duration information of the records can be viewed.

[0129] As Figure 13 shown, the embodiment of the present application provides an integrated intelligent verification method for a diesel generator speed regulation system, which is applied to the integrated intelligent verification system 100 of the diesel generator speed regulation system as described above. The integrated intelligent verification method for the diesel generator speed regulation system includes:

[0130] Step S100, simulating and outputting the working mode of the diesel generator, and providing test working parameters for the electronic governor 121 and the mechanical governor 111 based on the working mode of the diesel generator;

[0131] Step S200, collect in real time the working state parameters generated by the electronic governor 121 according to the test working parameters, display and analyze the working state parameters of the electronic governor 121, and collect in real time the working state parameters generated by the mechanical governor 111 according to the test working parameters, and display and analyze the working state parameters of the mechanical governor 111.

[0132] Those of ordinary skill in the art can understand that all or part of the steps of implementing the above method embodiments can be completed by hardware related to a computer program. The aforementioned computer program can be stored in a computer-readable storage medium. When the program is executed, it executes the steps including the above method embodiments; and the aforementioned storage medium includes: ROM, RAM, magnetic disk or optical disk and other various media that can store program codes.

[0133] The embodiment of the present application also provides a computer-readable storage medium, on which a computer program is cached, and when the computer program is executed by a processor, it implements the integrated intelligent verification method of the diesel generator speed regulation system provided by the embodiment of the present application.

[0134] In the embodiment of the present application, any combination of one or more storage media can be adopted. The storage medium can be a computer-readable signal medium or a computer-readable storage medium. The computer-readable storage medium can be, for example, but not limited to, an electrical, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any combination of the above. More specific examples (non-exhaustive list) of the computer-readable storage medium include: an electrical connection with one or more wires, a portable computer disk, a hard disk, RAM, ROM, erasable programmable read-only memory (EPROM or flash memory), an optical fiber, a portable compact disk read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the above. In this document, the computer-readable storage medium can be any tangible medium that contains or caches a program, and the program can be used by or in combination with an instruction execution system, apparatus, or device.

[0135] The embodiment of the present application also provides an electronic device. Figure 14The structure diagram of the electronic device 10 provided by the embodiments of the present application is shown. In some embodiments, the electronic device may be a mobile phone, a tablet computer, a wearable device, a vehicle-mounted device, an augmented reality (AR) / virtual reality (VR) device, a laptop computer, an ultra-mobile personal computer (UMPC), a netbook, a personal digital assistant (PDA), or other terminal devices. In addition, the integrated intelligent verification method for the diesel generator speed regulation system provided by the present application can also be applied to databases, servers, and service response systems based on terminal artificial intelligence. The embodiments of the present application do not impose any restrictions on the specific application scenarios of the integrated intelligent verification method for the diesel generator speed regulation system.

[0136] As Figure 14 shown, the electronic device 10 provided by the embodiments of the present application includes a memory 101 and a processor 102.

[0137] The memory 101 is used to cache computer programs; preferably, the memory 101 includes: various media such as ROM, RAM, magnetic disks, USB flash drives, cache cards, or optical discs that can cache program codes.

[0138] Specifically, the memory 101 may include a computer system readable medium in the form of volatile memory, such as random access memory (RAM) and / or cache memory. The electronic device 10 may further include other removable / non-removable, volatile / non-volatile computer system storage media. The memory 101 may include at least one program product, and this program product has a set (for example, at least one) of program modules, and these program modules are configured to execute the functions of the embodiments of the present application.

[0139] The processor 102 is connected to the memory 101 and is used to execute the computer program cached in the memory 101, so that the electronic device 10 executes the integrated intelligent verification method for the diesel generator speed regulation system provided in any embodiment of the present application.

[0140] Optionally, the processor 102 may be a general-purpose processor, including a Central Processing Unit (CPU), a Network Processor (NP), etc.; it may also be a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components.

[0141] Optionally, the electronic device 10 in this embodiment may further include a display 103. The display 103 is communicatively connected to the memory 101 and the processor 102, and is configured to display the relevant GUI interaction interface of the integrated intelligent verification method for the diesel generator speed regulation system.

[0142] Furthermore, the electronic device 10 further includes other components such as a firewall, a load balancer, a communication component, a power supply component, etc. Figure 14 Only some components are schematically shown, and it does not mean that the electronic device only includes Figure 14 the components shown.

[0143] The above embodiments may be implemented in whole or in part by software, hardware, firmware, or any other combination. When implemented using software, the above embodiments may be implemented in whole or in part in the form of a computer program product. The computer program product includes a plurality of computer instructions. When the computer instructions are loaded or executed on a computer, the processes or functions according to the embodiments of the present invention are generated in whole or in part. The computer may be a general-purpose computer, a special-purpose computer, a computer network, or other programmable devices. The computer instructions may be stored in a computer-readable storage medium, or transmitted from one computer-readable storage medium to another computer-readable storage medium.

[0144] In summary, the integrated intelligent calibration system for the diesel generator speed control system provided by this application can simultaneously test and evaluate the operating states of the mechanical governor and the electronic governor of the diesel generator speed control system, realizing the off-line detection and calibration analysis of the diesel generator speed control system, comprehensively monitoring the operating state of the diesel generator speed control system, reducing the fault judgment and decision-making time, reducing the unplanned unavailable time of the nuclear power emergency generator set, and increasing the safety and economic benefits of the nuclear power plant; the integrated intelligent calibration system for the diesel generator speed control system provided by this application can significantly reduce the return factory test and calibration costs of the mechanical governor and the electronic governor, ensuring the reliability and availability of the speed control system; the operators can be trained through this application, which can not only realize the detection of the diesel generator speed control system, but also achieve the purpose of technical training. Therefore, this application effectively overcomes various shortcomings in the prior art and has high industrial utilization value.

[0145] The above embodiments are only illustrative of the principles and effects of this application, and are not used to limit this application. Any person familiar with this technology can modify or change the above embodiments without departing from the spirit and scope of this application. Therefore, all equivalent modifications or changes completed by those with ordinary knowledge in the technical field without departing from the spirit and technical idea disclosed in this application should still be covered by the claims of this application.

Claims

1. An integrated intelligent calibration system for a diesel generator speed control system, characterized in that, Including: A mechanical speed regulation test bench, an electronic speed regulation test bench, and an intelligent calibration device; The mechanical speed regulation test bench includes a mechanical speed governor, a mechanical speed regulation transmission box for controlling the operation of the mechanical speed governor, a detection device for detecting the working state parameters of the mechanical speed governor, and a dashboard for displaying the operation state parameters of the mechanical speed governor; The electronic speed regulation test bench includes an electronic speed governor and a support frame for supporting the electronic speed governor; The intelligent calibration device is installed on the support frame and includes an upper computer device and a lower computer device; The upper computer device is used to simulate and output the working mode of a diesel generator, and provide test working parameters for the electronic speed governor and the mechanical speed governor based on the working mode of the diesel generator; The lower computer device is respectively connected to the upper computer device, the electronic speed governor, the mechanical speed control box, and the detection device, and is used to correspondingly send the test working parameters to the electronic speed governor and the mechanical speed governor, and collect in real time the working state parameters of the electronic speed governor and the working state parameters of the mechanical speed governor and send them to the upper computer device. The upper computer device displays and analyzes the working state parameters of the electronic speed governor and the working state parameters of the mechanical speed governor to calibrate the electronic speed governor and the mechanical speed governor.

2. The integrated intelligent calibration system of the diesel generator speed regulation system according to claim 1, characterized in that, A servo motor, an oil pump motor, a filter, a valve group, an oil tank oil circuit, a lubrication pipeline, a heating device, a temperature sensor, and a pressure regulating system are installed in the mechanical speed regulation transmission box; The detection device includes a speed sensor and an angle sensor installed on the mechanical speed governor; The dashboard includes a DC power supply display meter, a tachometer, a thermometer, an oil pressure gauge, and an indicator light.

3. The integrated intelligent calibration system of the diesel generator speed regulation system according to claim 1, characterized in that The electronic speed regulation test bench further includes: an auxiliary analysis terminal connected to the electronic speed governor; the auxiliary analysis terminal is installed with preset test software for reading and writing the set parameters in the electronic speed governor and recording the change of the working parameters of the electronic speed governor.

4. The integrated intelligent calibration system for the diesel generator speed regulation system according to claim 1, characterized in that, The following modules are configured in the upper computer device: a diesel generator simulation module, an electronic speed governor simulation test module, and a mechanical speed governor simulation test module; The diesel generator simulation module is used to simulate and output the working mode of a diesel generator, and input test working parameters to the electronic speed governor and the mechanical speed governor based on the working mode of the diesel generator and the lower computer device; The electronic speed governor simulation test module collects in real time the working state parameters generated by the electronic speed governor according to the test working parameters through the lower computer device, and displays and analyzes the working state parameters of the electronic speed governor; The mechanical speed governor simulation test module collects in real time the working state parameters of the mechanical speed governor through the lower computer device, and displays and analyzes the working state parameters of the mechanical speed governor.

5. The integrated intelligent calibration system of the diesel generator speed regulation system according to claim 4, characterized in that, The diesel generator simulation module includes: A modal control unit that generates a test signal or a simulation signal corresponding to the operating mode of the diesel generator based on the operating mode of the diesel generator; the test signal and the simulation signal respectively include a parameter command signal and a synchronization signal; the operating modes of the diesel generator include one or more combinations of the following: start / stop, trip / disconnect switch / closing switch, normal / emergency start mode, idle start / full-speed start mode, speed drop speed regulation mode / constant speed regulation mode, speed increase, speed decrease, two independent analog speeds, and mechanical governor speed; A signal output control unit that outputs the parameter command signal to the corresponding electronic governor or mechanical governor through the lower computer module, and outputs the synchronization signal to the lower computer module for the lower computer module to control the output of the parameter command signal; wherein, the parameter command signal is sent one by one according to the message queue, and the synchronization signal is sent repeatedly at equal intervals.

6. The integrated intelligent calibration system of the diesel generator speed regulation system according to claim 5, characterized in that, The diesel generator simulation module further includes: A modal recording unit for recording the changes in the operating mode of the diesel generator; A modal change display unit that generates and real-time displays a change curve of the operating mode of the diesel generator according to the recorded changes in the operating mode of the diesel generator.

7. The integrated intelligent calibration system of the diesel generator speed regulation system according to claim 4, characterized in that, The upper computer device is further configured with: a parameter configuration module for configuring the acquisition variables to be acquired from the electronic governor and the mechanical governor; wherein, the acquisition variables are configured as display variables and non-display variables.

8. The integrated intelligent calibration system of the diesel generator speed regulation system according to claim 4, characterized in that, The electronic governor simulation test module includes: A status parameter display unit for generating a continuous change curve of the operating status parameters of the electronic governor based on the changes in the operating status parameters of the electronic governor corresponding to the display variables; the operating status parameters of the electronic governor include digital quantity changes, operating current display, actual speed measurement, speed set value, number of speed probe failures, and number of watchdog failures; A channel waveform unit for recording and displaying the waveforms of each channel of the electronic governor; An electronic governor fault analysis unit for analyzing and obtaining the fault status of the electronic governor based on the operating status parameters of the electronic governor.

9. The integrated intelligent calibration system for the diesel generator speed control system according to claim 4, characterized in that, The mechanical governor simulation test module includes: An operating status acquisition and display unit for acquiring and displaying the operating status of the mechanical governor during different speeds, acceleration, and deceleration processes; A status change acquisition and display unit for acquiring and displaying the change in the output angle of the mechanical governor and the status change of the throttle rack; A curve recording unit for recording any one or more combinations of the speed curve, current curve, and rack curve of the mechanical governor according to the operating status and status changes; A mechanical governor fault analysis unit for judging whether the mechanical governor has jitter or stall according to the operating status and status changes.

10. An integrated intelligent calibration method for a diesel generator speed regulation system, which is applied to the integrated intelligent calibration system of the diesel generator speed regulation system according to any one of claims 1 to 9, characterized in that, It includes: Simulating and outputting the operating mode of the diesel generator, and providing test working parameters for the electronic governor and the mechanical governor based on the operating mode of the diesel generator; Collect in real time the operating status parameters generated by the electronic governor according to the test operating parameters, display and analyze the operating status parameters of the electronic governor, and collect in real time the operating status parameters generated by the mechanical governor according to the test operating parameters, and display and analyze the operating status parameters of the mechanical governor.

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