Electrolytic bath tension test system and test method thereof

Abstract

The invention discloses an electrolytic bath tension testing method, and relates to the technical field of electrolytic bath testing, the electrolytic bath tension testing method comprises an FPGA control core, an execution mechanism module and a sensor module, the FPGA control core comprises an FPGA main control unit, and the FPGA main control unit loads a configuration file for a corresponding electrolytic bath type for testing; the FPGA main control unit is connected to the working condition simulation cooperation core, the multi-channel synchronous acquisition core, the real-time processing acceleration core, the dynamic control core and the tension applying execution system; the working condition simulation collaborative core is in communication connection with the execution mechanism module, the collaborative execution mechanism module adjusts a plurality of working condition parameters, all channels of the multi-channel synchronous acquisition core are triggered by the same global clock, synchronous sampling is performed on the sensor module, and a result is transmitted to the real-time processing acceleration core for operation; and the dynamic control core drives the tension applying execution system to perform a tension test. And high-precision and high-dynamic testing of the tensile force of the electrolytic cell is realized.

Description

Technical Field

[0001] This invention relates to the field of electrolytic cell testing technology, and in particular to an electrolytic cell tensile testing system and its testing method. Background Technology

[0002] During operation, the dynamic tensile force borne by key components such as electrodes, diaphragms, and connectors of an electrolyzer is a core indicator for evaluating equipment reliability. Traditional testing systems employ a "sensor-microcontroller-host computer" architecture, which suffers from the following bottlenecks: First, data processing latency exceeds 100ms, making it impossible to capture the peak impact force of instantaneous component breakage; second, multi-sensor synchronization error exceeds 50μs, resulting in poor spatiotemporal matching of temperature, pressure, and tensile force data; and third, the control algorithm is fixed, making it difficult to dynamically adjust testing strategies for different electrolyzer types (such as alkaline electrolyzers and proton exchange membrane electrolyzers). Summary of the Invention

[0003] The purpose of this invention is to provide an electrolytic cell tensile testing system and method. Utilizing an FPGA embedded system, an electrolytic cell tensile testing system with the FPGA as its absolute core is constructed. The parallel computing capability of the FPGA solves the problem of synchronous acquisition of multiple parameters. Its hardware reconfigurability enables dynamic adaptation of the testing algorithm. Nanosecond-level control precision is used to capture transient tensile characteristics, ultimately achieving breakthroughs in the "real-time performance, accuracy, and adaptability" of electrolytic cell component tensile testing. Through its high-performance computing and real-time control characteristics, high-precision and high-dynamic testing of electrolytic cell tensile forces is achieved.

[0004] The above-mentioned technical objective of the present invention is achieved through the following technical solution: An electrolytic cell tensile testing system includes an FPGA control core, an actuator module, and a sensor module. The FPGA control core includes an FPGA main control unit, which loads a configuration file for the corresponding electrolytic cell type for testing. The FPGA main control unit is connected to a working condition simulation and coordination core, a multi-channel synchronous acquisition core, a real-time processing acceleration core, a dynamic control core, and a tensile application execution system. The working condition simulation collaborative core is connected to the actuator module. The collaborative actuator module adjusts multiple working condition parameters. All channels of the multi-channel synchronous acquisition core are triggered by the same global clock to synchronously sample the sensor module and transmit the data to the real-time processing acceleration core for calculation. The dynamic control core drives the tensile force application execution system to perform tensile testing.

[0005] Furthermore, the sensor module includes several force sensors, displacement sensors, and temperature sensors.

[0006] Furthermore, the real-time processing acceleration core includes a tensile peak detection module, a tensile-displacement curve fitting module, and a temperature drift compensation module.

[0007] Furthermore, the real-time processing acceleration core sends the processed data to the data storage module and / or data analysis module.

[0008] Furthermore, the actuator module includes a temperature control module, a pressure control module, and an electrolyte circulation module.

[0009] Furthermore, it also includes a corrosion-resistant testing chamber with built-in corrosion-resistant fixtures and a camera. The corrosion-resistant fixtures clamp the electrolytic cell components and apply tension through a tension application actuator, while the camera monitors the process of surface crack formation on the electrolytic cell components in real time.

[0010] A method for testing the tensile strength of an electrolytic cell includes the following steps: The FPGA control core is initialized and a configuration file for the corresponding electrolytic cell type is loaded for testing; the FPGA main control unit sends synchronization pulses to the co-actuator module through the working condition simulation and coordination core to adjust multiple working condition parameters to achieve preset values; Then, dynamic tensile loading and real-time analysis are performed. The FPGA main control unit generates control commands according to the preset loading curve to control the tensile force application execution system. At regular intervals, the multi-channel synchronous acquisition core collects data from the sensor module and the acceleration core performs calculations in real time. When the sensor module detects that the tensile force drops by more than a preset percentage, the FPGA main control unit triggers the protection mechanism, cuts off the tensile force output of the tensile force application execution system, and records all parameters within the set time period before the fracture.

[0011] Furthermore, the calculations performed by the acceleration kernel include calculating the instantaneous tensile force, plotting the slope of the tensile-displacement curve, and determining whether the yield point has been reached.

[0012] Furthermore, the data processed in real time after the accelerated core operation is sent to the data analysis module, which then runs a fault diagnosis algorithm to determine the effectiveness of the test in real time.

[0013] Furthermore, after the test is completed, the FPGA control core generates a test report, which includes the transient tensile peak value, yield strength, and temperature influence coefficient.

[0014] In summary, the present invention has the following beneficial effects: 1. Significant improvement in synchronization accuracy: The global clock synchronization mechanism of the FPGA controls the acquisition time difference of 128 sensors within 1ns, solving the problem of spatiotemporal mismatch of multiple parameters in traditional systems and ensuring accurate analysis of the correlation between tensile force and environmental parameters.

[0015] 2. Breakthrough in transient response: The peak detection speed of 10ns can capture the impact force peak at the moment of component fracture (traditional systems would lose this data due to delay), providing key data for the impact resistance performance evaluation of brittle materials (such as ceramic diaphragms).

[0016] 3. Enhanced Algorithm Adaptability: The reconfigurable hardware allows the same device to adapt to the testing needs of different types of electrolytic cells. For example, a humidity compensation algorithm can be loaded for proton exchange membrane electrolytic cells, and an alkaline corrosion correction model can be enabled for alkaline electrolytic cells. The switching time is less than 1 second, saving more than 90% of the time compared to the mechanical modification of traditional equipment.

[0017] 4. Improved control bandwidth: The 10kHz PID control bandwidth increases the dynamic response speed of tensile loading by 10 times, and can accurately reproduce the pulse-like tensile force changes during the start-up and shutdown of the electrolytic cell (traditional systems will cause waveform distortion due to insufficient bandwidth).

[0018] 5. Enhanced reliability: The FPGA's operating system-free architecture avoids the risk of software crashes, and all critical modules are designed with hardware-level redundancy. In the event of a single point of failure, it automatically switches to backup logic, with a mean time between failures (MTBF) of 100,000 hours. Attached Figure Description

[0019] To more clearly illustrate the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the principle of an electrolytic cell tensile testing system according to the present invention. Detailed Implementation

[0021] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings. These embodiments do not constitute a limitation of the present invention. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this application.

[0022] An electrolytic cell tensile testing system, such as Figure 1 As shown, it includes an FPGA control core, an actuator module, and a sensor module. The FPGA control core includes an FPGA main control unit, which loads a configuration file for the corresponding electrolytic cell type for testing. It uses a Xilinx UltraScale+ series FPGA chip. The FPGA control core also integrates the following modules. 1. The FPGA main control unit is connected to a multi-channel synchronous acquisition core. This core has a built-in 128-channel 16-bit ADC controller for synchronous sampling of the sensor modules. The sampling rate reaches 1 MSPS, and all channels are triggered by the same global clock, with a synchronization error ≤1 ns. The sensor modules include several force sensors (range 0-20kN, accuracy 0.1%FS), displacement sensors (resolution 0.1μm), and temperature sensors (-50~200℃, accuracy ±0.5℃). The multi-channel synchronous acquisition core designs dedicated interface IP cores for the force, displacement, and temperature sensors to achieve direct signal digitization.

[0023] 2. The real-time processing acceleration core includes a peak tensile force detection module (response time <10ns), a tensile force-displacement curve fitting module (hardware acceleration using the least squares method), and a temperature drift compensation module (hardware implementation based on BP neural network). All algorithms are solidified in VerilogHDL, with a processing latency of <1μs. The real-time processing acceleration core sends the processed data to the data storage module and the data analysis module.

[0024] 3. The tension application execution system consists of 8 permanent magnet synchronous servo motors, each equipped with a 17-bit absolute encoder. Distributed control is achieved through the EtherCAT interface of the FPGA, with a position control accuracy of ±0.01mm and a tension control accuracy of ±0.1% FS, for tensile testing of components.

[0025] 4. The dynamic control core drives the tension application execution system, which performs tension testing; the dynamic control core outputs 16 PWM signals (frequency adjustable range 100Hz-1MHz), which can directly drive the servo motor of the tension application unit; its built-in PID controller IP core, the proportional coefficient, integral time, and derivative time can be dynamically configured by the host computer, and the control bandwidth is ≥10kHz.

[0026] 5. The working condition simulation collaborative core is connected to the actuator module. It coordinates with the actuator module to adjust multiple working condition parameters and transmits them to the real-time processing acceleration core for calculation. The actuator module specifically includes a temperature control module (PID regulation, control accuracy ±1℃), a pressure control module (0-5MPa, accuracy ±0.01MPa), and an electrolyte circulation module (flow rate 0-50L / min, accuracy ±0.1L / min). The working condition simulation collaborative core establishes high-speed communication with the temperature control module, pressure control module, and electrolyte circulation module to realize the coordinated adjustment of multiple working condition parameters. The adjustment command generation cycle is <10μs.

[0027] 6. Corrosion Resistance Test Chamber: Made of 316L stainless steel, with built-in corrosion-resistant clamps (compatible with electrodes of φ10-100mm and diaphragms of 50-500mm²). The corrosion-resistant clamps hold the electrolytic cell components and apply tension through the tension application actuator. The chamber is equipped with an FPGA-controlled multispectral camera to monitor the crack generation process on the surface of the components in real time.

[0028] 7. Host Computer Interaction Layer: Communicates with the FPGA via 10G Ethernet. It is mainly responsible for configuring test parameters (such as tensile loading curves and operating parameters) and visualizing test results. All real-time data processing is completed on the FPGA side, and the host computer only receives the processed result data.

[0029] This embodiment also discloses a method for testing the tensile strength of an electrolytic cell, including the following steps. Step S10, FPGA control core initialization and parameter configuration: After power-on, the FPGA control core automatically loads the configuration file for the specific electrolytic cell type (such as enabling the high temperature compensation algorithm for alkaline electrolytic cells, loading the humidity compensation algorithm for proton exchange membrane electrolytic cells, etc.), completes the writing of sensor calibration coefficients through the JTAG interface, and establishes a 128-bit encrypted communication link to synchronize parameters with the host computer.

[0030] Step S20, Multi-physics field synchronous start-up: The FPGA main control unit sends a synchronization pulse to the collaborative actuator module through the working condition simulation collaborative core, and adjusts multiple working condition parameters to reach the preset value; Specifically, the FPGA main control unit sends synchronization pulses to the temperature control module, pressure control module, and electrolyte circulation module to bring the chamber environment to preset values ​​(such as 80℃, 0.3MPa, and electrolyte flow rate of 15L / min) within 50ms. The synchronization error is recorded by the FPGA timestamp module to ensure ≤5ms.

[0031] Step S30, dynamic tensile force loading and real-time analysis; specifically including, In step S31, the FPGA main control unit generates control commands based on the preset loading curve (such as sine wave loading: 5000N amplitude, 0.5Hz frequency) to control the tension application execution system to work. Closed-loop control of the tension is achieved through the servo driver, with a control cycle of 100μs.

[0032] Step S32: The multi-channel synchronous acquisition core collects data from the sensor module every 1μs, and the real-time processing acceleration core performs calculations to determine whether the yield point has been reached. In this embodiment, the force sensor and displacement sensor data are collected once every 1μs. The real-time processing module completes the following calculations within 10 clock cycles: calculates the instantaneous tensile force value (removing the influence of temperature drift), plots the slope of the tensile force-displacement curve, and determines whether the yield point has been reached.

[0033] Step S33: When the sensor module detects a sudden drop in tension greater than a preset percentage, in this embodiment, the sudden drop in tension is detected to be >5% (which may be due to component breakage). The FPGA main control unit immediately triggers the protection mechanism, cuts off the tension output of the tension application execution system within 200ns, and records all parameters (resolution 1μs) in the 10ms before the breakage.

[0034] Step S40: The FPGA main control unit performs local data storage and analysis: Test data is temporarily stored in the data storage module, which is a 4GB DDR4 memory (12.8GB / s bandwidth) external to the FPGA. It has a built-in data compression core (compression ratio 3:1) to reduce storage usage. At the same time, it is sent to the data analysis module, which runs a fault diagnosis algorithm (based on decision tree hardware implementation) to judge the validity of the test in real time.

[0035] Step S50, Result Output and Algorithm Reconstruction: After the test, the FPGA control core generates a test report containing 200 parameters (including transient tensile peak, yield strength, temperature influence coefficient, etc.), and uploads it to the host computer via the PCIe interface; If the test object needs to be changed, simply load the new algorithm configuration file through the network port, and the FPGA will complete the logic reconfiguration within 1 second without any hardware changes.

[0036] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art can make various modifications or equivalent substitutions to the present invention within the scope of its essence and protection. Such modifications or equivalent substitutions should also be considered to fall within the protection scope of the present invention.

Claims

1. A tensile testing system for an electrolytic cell, characterized in that: It includes an FPGA control core, an actuator module, and a sensor module. The FPGA control core includes an FPGA main control unit, which loads a configuration file for the corresponding electrolytic cell type for testing. The FPGA main control unit is connected to the working condition simulation and coordination core, the multi-channel synchronous acquisition core, the real-time processing acceleration core, the dynamic control core, and the tension application execution system. The working condition simulation collaborative core is connected to the actuator module. The collaborative actuator module adjusts multiple working condition parameters. All channels of the multi-channel synchronous acquisition core are triggered by the same global clock to synchronously sample the sensor module and transmit the data to the real-time processing acceleration core for calculation. The dynamic control core drives the tensile force application execution system to perform tensile testing.

2. The electrolytic cell tensile testing system according to claim 1, characterized in that: The sensor module includes several force sensors, displacement sensors, and temperature sensors.

3. The electrolytic cell tensile testing system according to claim 2, characterized in that: The real-time processing acceleration core includes a tensile peak detection module, a tensile-displacement curve fitting module, and a temperature drift compensation module.

4. The electrolytic cell tensile testing system according to claim 1, characterized in that: The real-time processing acceleration core sends the processed data to the data storage module and / or data analysis module.

5. The electrolytic cell tensile testing system according to claim 1, characterized in that: The actuator module includes a temperature control module, a pressure control module, and an electrolyte circulation module.

6. The electrolytic cell tensile testing system according to claim 1 or 5, characterized in that: It also includes a corrosion-resistant test chamber with built-in corrosion-resistant fixtures and a camera. The corrosion-resistant fixtures clamp the electrolytic cell components and apply tension through a tension application actuator. The camera monitors the process of surface crack formation on the electrolytic cell components in real time.

7. A testing method based on the electrolytic cell tensile testing system of claim 1, characterized in that: Includes the following steps, The FPGA control core is initialized and a configuration file for the corresponding electrolytic cell type is loaded for testing; the FPGA main control unit sends synchronization pulses to the co-actuator module through the working condition simulation and coordination core to adjust multiple working condition parameters to achieve preset values; Then, dynamic tensile loading and real-time analysis are performed. The FPGA main control unit generates control commands according to the preset loading curve to control the tensile force application execution system. At regular intervals, the multi-channel synchronous acquisition core collects data from the sensor module and the acceleration core performs calculations in real time. When the sensor module detects that the tensile force drops by more than a preset percentage, the FPGA main control unit triggers the protection mechanism, cuts off the tensile force output of the tensile force application execution system, and records all parameters within the set time period before the fracture.

8. The testing method of the electrolytic cell tensile testing system according to claim 7, characterized in that: The calculations performed by the acceleration kernel include calculating the instantaneous tensile force, plotting the slope of the tensile-displacement curve, and determining whether the yield point has been reached.

9. The testing method of the electrolytic cell tensile testing system according to claim 7 or 8, characterized in that: The data processed in real time after acceleration is sent to the data analysis module, which then runs a fault diagnosis algorithm to determine the effectiveness of the test in real time.

10. The testing method of the electrolytic cell tensile testing system according to claim 7 or 8, characterized in that: After the test, the FPGA control core generates a test report, which includes the transient tensile peak value, yield strength, and temperature influence coefficient.

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