Multifunctional gas turbine digital detector

Abstract

The invention discloses a multifunctional gas turbine digital detector, which belongs to the field of gas turbine detection and comprises a hardware system and a software system. The hardware system is a basic carrier for detection, is responsible for signal acquisition, transmission and processing, and comprises a main control module, a signal acquisition module, a case, a reinforcing machine platform and a communication module. The main control module serves as a core control unit and is connected with the signal acquisition module and the communication module through a bus in a case, and centralized processing of data and instruction issuing are achieved. The ruggedized machine platform carries a software system, provides a hardware environment for software operation, and communicates with the main control module to complete data interaction; the device has the advantages of being small in size, light in weight, convenient to move, high in automation degree and convenient to use in an external field, the basis can be provided for internal and external field inspection, parameter adjustment and fault removal, the maintenance work efficiency can be greatly improved, the maintenance cost can be saved, and huge economic benefits can be brought.

Description

Technical Field

[0001] This invention relates to the field of gas turbine testing technology, and in particular to a multifunctional digital gas turbine testing instrument. Background Technology

[0002] As a crucial power source, the operational stability and reliability of gas turbines directly impact related industrial production and energy supply. Before and during operation, the control system and related parameters of a gas turbine must be tested to ensure normal start-up and operation, and to promptly identify potential faults.

[0003] Existing gas turbine testing equipment has the following shortcomings: it relies on imported hardware, resulting in poor compatibility and high cost; the signal acquisition accuracy is insufficient, making it difficult to meet the requirements for high-precision parameter testing; the degree of automation is low, requiring a lot of manual intervention and resulting in low testing efficiency; it lacks comprehensive simulation and monitoring functions, making it impossible to simulate various operating conditions of gas turbines and monitor key parameters in real time; and its adaptability is limited, making it difficult to simultaneously meet the needs of indoor laboratory testing and outdoor mobile testing.

[0004] Therefore, there is a need for a gas turbine digital testing instrument based on domestically produced hardware, with high precision, automation, simulation and monitoring functions, and adaptable to both indoor and outdoor use, to solve the problems of poor compatibility, insufficient accuracy, low degree of automation, and limited adaptability of existing gas turbine testing equipment. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a multifunctional digital gas turbine detector to solve problems such as poor compatibility, insufficient accuracy, low automation, and limited adaptability of existing gas turbine testing equipment.

[0006] Technical solution: To solve the above-mentioned technical problems, according to one aspect of the present invention, a more specific multi-functional digital gas turbine detector includes a hardware system and a software system.

[0007] The hardware system is the basic carrier for detection, responsible for signal acquisition, transmission, and processing. It includes a main control module, a signal acquisition module, a chassis, a ruggedized platform, and a communication module. The main control module, as the core control unit, is connected to the signal acquisition module and the communication module via an internal bus within the chassis, enabling centralized data processing and command issuance. The ruggedized platform carries the software system, providing the hardware environment for software operation and communicating with the main control module to complete data interaction.

[0008] The main control module uses domestically produced high-performance controllers, including the PE6750 and PE6760 models. The PE6750 is configured with a CPU of i7-5500U, 8GB of memory, and a 1TB hard drive; the PE6760 is configured with a CPU of i7-6820EQ, 32GB of memory, and a 2TB hard drive. These configurations can be selected according to testing requirements to ensure efficient processing of complex data.

[0009] The chassis is a PXIe cage, including JD6400 (4 slots) and JD6700 (7 slots), which provides installation space and bus connection support for each module. It can be selected according to the number of modules, improving the flexibility of hardware configuration.

[0010] Furthermore, the signal acquisition module is designed for various signals from the gas turbine, achieving comprehensive and high-precision acquisition, specifically including: Digital Input Module (CVC-DI6064): 64-channel DI for acquiring digital signals from the gas turbine; Digital output module (CVC-DO6064): 64-channel DO, outputting control signals; Analog input module (CVC-AI6032): 32-channel AI, supports ±40mA / -10~10V signals, accuracy 0.1%FS; Analog output module (CVC-AO6032): 32-channel AO, accuracy 0.1%FS; LVDT input module (CVC-LV6008): 8-channel LVDT, accuracy 0.1%FS; RTD module (CVC-RTD6012): 12-channel RTD, accuracy 0.1%FS; TC module (CVC-TC6032): 32-channel TC, supports measurement from -270℃ to 1372℃, with an accuracy of 0.1%FS; FO module (CVC-FO6008): 8-channel FO output, simulating a sine wave of rotational speed, with an accuracy of 0.1%FS; Pressure pulsation IEPE module (CVC-IE6004): 4-channel IEPE, for acquiring pressure pulsation signals; Current Acquisition and Control Card (CVC-AI6020): 20-channel current acquisition, 20 onboard relays, supports hardware / software control.

[0011] Furthermore, the communication module adopts a CAN communication module (CVC-CAN02), with 2 channels, to realize communication between the detector and the gas turbine and other equipment.

[0012] Furthermore, the ruggedized platform provides stable hardware support for testing, with the following configuration: CPU: Intel® Core™ I7-7500U (2.7GHz / 3.5GHz); Memory: 8GB DDR3 (upgradeable to 16GB); Storage: 512GB SSD (upgradeable to 1TB / 2TB); Operating System: Windows 7 / Windows 10; Supports 220V / 50Hz AC, 24V DC and lithium battery power supply (battery life ≥1h); Interface: Aviation plug type; Adaptable to operating temperature of -10℃~+50℃ and storage temperature of -40℃~+70℃, meeting the needs of indoor and outdoor use.

[0013] Furthermore, the software system works in conjunction with the hardware to achieve intelligent gas turbine detection, including: Equipment modeling software: Runs the gas turbine mathematical model, simulates the actual operation process, and outputs simulation parameters; Equipment controller software: controls the operation of the control signal acquisition module and controls actuators such as relays (hardware automatic control is based on FPGA to compare current and threshold values, and software control is based on software decision-making based on sampled values). Equipment status monitoring software: receives and displays gas turbine parameters (speed, temperature, pressure, vibration, etc.) in real time, and dynamically displays parameter change curves through charts; it also has a fault injection function to simulate faults such as extreme values, slope, and disconnection to assist in fault diagnosis.

[0014] Furthermore, the control interface of the device status monitoring software adopts a modular design, with the main interface integrating core function entry points and each module having a clear division of labor: The "Normal Start-up" module displays dynamic parameters in real time, including speed parameters such as gas generator speed Ng and power turbine speed Np, temperature parameters such as power turbine outlet total temperature T6, vibration parameters such as intake casing vertical vibration Vc1, lubricating oil parameters such as lubricating oil supply temperature Toil and total return oil temperature Toh, and blade angle parameters such as IGV blade angle setting and feedback. It also displays control parameters such as start-up time, fuel setting WfmDem, and fuel feedback Wfm, and records the status changes of key time nodes after ignition (such as shutting off the igniter 25 seconds after ignition, starting fuel supply at 2900 rpm, etc.).

[0015] The "Discrete Quantity Display" module centrally displays the control status (main control backup indicator, vortex vent valve status, feedforward mode, etc.), digital inputs and outputs, first-level / second-level / third-level alarm information and flags (cold engine flag, over-control flag, sensor fault flag, etc.); the "Analog Quantity Display" module presents analog parameters such as fuel inlet pressure Pin, gas turbine flow rate Wf, and total lubricating oil return temperature Toh in real time.

[0016] The “Chart Display” module supports dynamically displaying curves showing changes in key parameters (such as the power turbine speed Np and fuel input WfmDem curves). The curve display status can be selected through the option box, and the curve colors are distinctive.

[0017] Furthermore, the software system is developed to adapt to the characteristics of domestically produced hardware: The device controller software optimizes the control logic based on the hardware parameters of the signal acquisition module (such as 32 channels and 0.1%FS accuracy for CVC-AI6032, and 4 / 8 channels and 16-bit resolution for CVC-LV6008) to ensure the real-time performance and accuracy of signal acquisition.

[0018] For relay control of the current acquisition and control card (CVC-AI6020), the software is compatible with two modes: in hardware automatic control, the software sends threshold parameters to the FPGA, and the FPGA compares the current sample value with the threshold value; in software control, the software makes decisions directly based on the sample value and outputs control commands. The two modes can be switched through the software interface.

[0019] Furthermore, the simulation function of the equipment model software works in conjunction with the hardware to achieve high-precision simulation: after the software loads the mathematical model, it outputs analog parameter signals to the gas turbine controller through the CVC-AO6032 analog output module of the signal acquisition module, and at the same time receives the feedback signals from the controller through the CVC-DI6064 digital input module, forming a closed-loop simulation. The simulation data is processed by the main control module and displayed in real time on the software interface of the ruggedized machine platform, supporting researchers to virtually verify the gas turbine start-up and operation process.

[0020] The fault injection function of the software system is linked with the hardware acquisition module: when the simulated sensor fails (such as extreme value fault or disconnection fault), the software outputs an abnormal analog signal to the controller through the CVC-AI6032, and at the same time acquires the controller's response signal through the CVC-IE6004 pressure pulsation module. The equipment status monitoring software records the alarm event (including fault type and occurrence time), realizing the simulation of the entire fault troubleshooting process.

[0021] The beneficial effects of the multifunctional digital gas turbine detector of the present invention are as follows: (1) Based on the engine simulation model and the actuator model, this invention is a set of hardware devices including software for performing functional checks on the engine control system before normal start-up and for performing logic tests, status monitoring and data analysis during test runs. At the same time, the aviation equipment tester serves as ground support equipment and can be used for system verification and fault diagnosis. The aim is to ensure that the control system can execute the correct control logic and improve the reliability of the control system during test runs.

[0022] (2) As a support device for the detection and maintenance of engine electronic control system, the present invention has the characteristics of small size, light weight, easy to move, high degree of automation, convenient operation, and easy to use in the field. It can provide a basis for internal and external field inspection and adjustment of parameters and troubleshooting, which can greatly improve the efficiency of maintenance work, save maintenance costs, and bring huge economic benefits. Attached Figure Description

[0023] The present invention will now be described in further detail with reference to the accompanying drawings and specific implementation methods.

[0024] Figure 1 This is a schematic diagram of the hardware and software systems in this invention; Figure 2 This is a schematic diagram of the main interface of the software system in this invention; Figure 3 This is a schematic diagram of the structure of the present invention. Detailed Implementation

[0025] The present invention will be described in detail below with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in the present application can be combined with each other.

[0026] To make the technical solution of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0027] Reference Figures 1-3 A multi-functional digital gas turbine detector, comprising hardware and software systems. The hardware system configuration is as follows: Main control module: PE6760 main controller (CPU: i7-6820EQ, memory: 32G, hard disk: 2T); Chassis: JD6700 (7-slot PXIe chassis); Signal acquisition module: configured with CVC-DI6064 (digital input), CVC-DO6064 (digital output), CVC-AI6032 (analog input), CVC-LV6008 (LVDT input), CVC-TC6032 (TC input), CVC-IE6004 (IEPE input), and CVC-AI6020 (current acquisition). Communication module: CVC-CAN02 (CAN communication); Ruggedized platform: CPU i7-7500U, 16GB RAM, 1TB SSD storage, Windows 10 operating system.

[0028] The software system runs on a ruggedized platform, and its specific functions are as follows: Equipment model software: Loads the gas turbine mathematical model, simulates operating conditions such as 0.3 and 0.8, and outputs parameters such as Ng (gas turbine speed) and T6 (total outlet temperature of power turbine); Equipment controller software: controls the CVC-AI6032 to acquire analog signals from the gas turbine, and controls the relays of the CVC-AI6020 (in hardware automatic control mode, when the acquired current is higher than the threshold value (e.g., 50mA), the FPGA controls the relays to close). Equipment status monitoring software: Real-time display of parameters such as Ng, T6, and vibration value; Ng change curve over time is displayed in charts; Fault injection function is activated to simulate extreme T6 faults and observe system alarm response.

[0029] During the testing process, the hardware system collects gas turbine signals and transmits them to the main control module. The main control module then sends the data to the ruggedized machine platform. The software system processes and displays the data and outputs control commands as needed to complete the gas turbine testing.

[0030] Preferably, the operation of the software system is deeply coordinated with the hardware configuration: During the pre-start static check, the main control module (PE6760) controls the CVC-LV6008 module to output LVDT simulation signals. The equipment controller software issues commands through the software interface to detect the channel response of the controller. The "Discrete Quantity Display" module of the equipment status monitoring software refreshes the status of the switch input in real time to confirm the consistency between the command issuance and the feedback.

[0031] When simulating operating condition 0.8, the equipment model software loads the mathematical model corresponding to the operating condition and outputs simulated fuel flow and speed signals through the CVC-AO6032 module; the CVC-TC6032 module collects the temperature signal fed back by the controller (accuracy 0.1% FS) and transmits it to the rugged machine platform through the main control module; the "Chart Display" module of the equipment status monitoring software generates curves of Ng speed and T6 temperature changing over time, supporting curve saving and comparative analysis.

[0032] When expanding the health diagnostic function, the hardware configuration only retains the main control module, communication module (CVC-CAN02), and rugged platform. The software receives historical operating data from field equipment via CAN communication and performs graph analysis (such as temperature-pressure correlation graph) in the "Data Playback" module, without needing to enable the large channel resources of the signal acquisition module.

[0033] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A multi-functional digital gas turbine detector, comprising a hardware system and a software system, characterized in that: The hardware system includes a main control module, a signal acquisition module, a chassis, a ruggedized platform, and a communication module; The software system includes equipment model software, equipment controller software, and equipment status monitoring software. The main control module, signal acquisition module, and communication module are all connected via an internal bus. The ruggedized platform is equipped with a software system and is connected to the main control module. The signal acquisition module is used to acquire digital signals, analog signals, LVDT signals, RTD signals, TC signals, FO signals, and IEPE signals from the gas turbine. The equipment model software is used to run the gas turbine mathematical model and simulate the actual operation of the gas turbine. The equipment controller software is used to control signal acquisition and actuator actions; the equipment status monitoring software is used to monitor and display the gas turbine operating parameters in real time.

2. The multifunctional digital gas turbine detector according to claim 1, characterized in that, The main control module includes a main controller of model PE6750 and / or a main controller of model PE6760; The PE6750 main controller is configured with CPU: i7-5500U, memory: 8G, and hard disk: 1T. The PE6760 main controller is configured with CPU: i7-6820EQ, memory: 32G, and hard disk: 2T.

3. The multifunctional digital gas turbine detector according to claim 1, characterized in that, The chassis includes a PXIe cage of model JD6400 and / or a PXIe cage of model JD6700. The JD6400 is a 4-slot chassis, and the JD6700 is a 7-slot chassis.

4. The multifunctional digital gas turbine detector according to claim 1, characterized in that, The signal acquisition module includes: The digital input module, model CVC-DI6064, is a 64-channel DI module; The digital output module, model CVC-DO6064, is a 64-channel DO module; The analog input module, model CVC-AI6032, is a 32-channel AI module that supports ±40mA / -10~10V signals with an accuracy of 0.1%FS. The analog output module, model CVC-AO6032, is a 32-channel AO module with an accuracy of 0.1%FS. The LVDT input module, model CVC-LV6008, is an 8-channel LVDT module with an accuracy of 0.1%FS; The RTD module, model CVC-RTD6012, is a 12-channel RTD module with an accuracy of 0.1%FS. The TC module, model CVC-TC6032, is a 32-channel TC module that supports measurements from -270℃ to 1372℃ with an accuracy of 0.1%FS. The FO module, model CVC-FO6008, is an 8-channel FO output module that simulates a sine wave of rotational speed with an accuracy of 0.1%FS. The pressure pulsation IEPE module, model CVC-IE6004, is a 4-channel IEPE module; The current acquisition and control card, model CVC-AI6020, is a 20-channel current acquisition module with 20 onboard relays, supporting both hardware automatic control and software control.

5. The multifunctional digital gas turbine detector according to claim 1, characterized in that, The communication module includes a CAN communication module of model CVC-CAN02, which is a 2-channel CAN communication card.

6. The multifunctional digital gas turbine detector according to claim 1, characterized in that, The ruggedized platform is configured with: an Intel® Core™ I7-7500U CPU with a frequency of 2.7GHz / 3.5GHz; 8GB DDR3 memory; 512GB SSD storage; Windows 7 / Windows 10 operating system; support for 220V / 50Hz AC power supply, 24V DC power supply and lithium battery power supply; an aviation plug-in interface; an operating temperature range of -10℃ to +50℃ and a storage temperature range of -40℃ to +70℃.

7. The multifunctional digital gas turbine detector according to claim 1, characterized in that, The equipment status monitoring software has a parameter display function, which can display speed, temperature, pressure, vibration, blade angle, fuel parameters and lubricating oil parameters; it also has a chart display function, which can dynamically display the change curves of key parameters and supports curve selection display. The software system also has a fault injection function, which can simulate gas turbine parameter faults, sensor faults and communication faults; the faults include extreme value faults, slope faults and disconnection faults.

8. The multifunctional digital gas turbine detector according to claim 1, characterized in that, The device controller software supports relay control, including hardware automatic control and software control; During the automatic hardware control, the current sample value is compared with the threshold value based on the FPGA. If the current sample value is higher than the threshold value, the relay is automatically closed. In the software control mode, the relay is closed based on the sampled values.

9. The multifunctional digital gas turbine detector according to claim 1, characterized in that, The CVC-LV6008 module in the signal acquisition module supports 4 / 8 channel LVDT / RVDT simulation, 16-bit resolution, receives 47Hz~10KHz excitation signals, adapts to 1V~7V AC effective value excitation signals, outputs peak-to-peak value ≤20V signals, and has an accuracy of 0.5%FS.

10. The multifunctional digital gas turbine detector according to claim 1, characterized in that, The control interface of the equipment status monitoring software includes multiple functional modules, specifically including "Start-up and Inspection", "Inspection and Control", "Normal Start-up", "Cold Operation", "Debugging Interface", "Discrete Quantity Display", "Analog Quantity Display", "Chart Display", "Channel Detection" and "Data Playback" modules, and supports interface switching, program exit, user management, test run information configuration and software version identification functions; The "Start-up and Inspection" module can display start-up interlock conditions and corresponding inspection indicators. The start-up interlock conditions include starter ready, no stop signal, lubricating oil temperature (Toil) meeting start-up conditions, fuel level meeting start-up conditions, and control cabinet fault-free operation. It supports inspection and control of cold operation, oil seal, unsealing, cleaning, testing, oil leveling, and dummy start processes. The "Data Playback" module supports secondary playback analysis of stored test data to trace back the equipment's operating status. The software system is independently developed and has undergone multiple iterations. The third-generation software achieves domestic substitution. The gas turbine mathematical model running the equipment model software is confidential and can simulate various operating states such as 0.3 and 0.8 conditions. It supports input of analog numerical values ​​(100, 100.1, etc.) or discrete states (0 or 1), outputs corresponding parameter curves and compares them with the set curves to verify the correctness of the parameters. The combination of the software system and the hardware system has differentiated adaptation characteristics: when used for detection functions, the software controls the signal acquisition module (including CVC-DI6064, CVC-AI6032, etc.) to perform real-time acquisition, and the hardware is configured with a multi-slot chassis (such as JD6700) to accommodate the acquisition card; when expanding the health diagnosis function, the software receives data from the field equipment through the communication module, and the hardware does not need to be configured with a large number of acquisition cards.

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