Diesel generating set intelligent control assembly and method thereof

Abstract

The invention discloses an intelligent control assembly and method for a diesel generating set. The assembly comprises a diesel engine control device, a generator control device and an intelligent terminal. The core of the diesel engine control device is that the diesel engine control device adopts an innovative mechanical executing mechanism, a winding component (such as a wheel disc) is driven by a motor to take up and pay off a control cable, physical accurate control over an accelerator and flameout of a traditional diesel engine is achieved, and safety protection is preferably provided through a hardware limiting switch. The device and a generator control device work cooperatively through an internal bus, advanced functions such as automatic frequency adjustment can be achieved, and a user can conduct remote monitoring through an intelligent terminal. According to the invention, an expensive special electronic speed regulator (ECU) is completely abandoned, and the system has the outstanding advantages of extremely low cost, extremely high reliability and extremely good compatibility, and is an ideal solution for intelligent upgrading of a traditional diesel generating set.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of diesel generator set control, in particular to an intelligent control assembly for realizing bottom-layer precise control of a diesel generator set and a collaborative control method thereof. BACKGROUND

[0002] As an important backup or main power source, the automation and intelligence level of a diesel generator set is crucial. The mainstream scheme for realizing automatic control at present is to use a highly integrated special electronic controller (such as an electronic governor ECU or an automatic voltage regulator AVR). Although this scheme has high control precision, it has significant defects: first, the cost is extremely high, which greatly increases the unit cost and makes it difficult to be popularized in the market, especially for the intelligent transformation of the vast number of traditional units; second, the universality is poor, and the special controller is usually bound to a specific engine or generator model; finally, the maintenance is difficult, and once the controller fails as a whole, it often needs to be replaced as a whole, which has high maintenance cost and long maintenance period. SUMMARY

[0003] (I) Invention purpose The purpose of the present application is to overcome the shortcomings of the existing integrated controller scheme and provide an intelligent control assembly for a diesel generator set and a method thereof. The assembly, through an innovative and non-obvious hardware architecture, especially a high-reliability mechanical actuator, realizes comprehensive intelligent control functions while significantly reducing cost, improving reliability and equipment compatibility.

[0004] (II) Technical scheme To achieve the above purpose, the present application adopts the following technical scheme: An intelligent control assembly for a diesel generator set, comprising: a diesel engine control device, a generator control device and at least one intelligent terminal; The diesel engine control device comprises a first MCU, a mechanical actuator and a first set of signal acquisition modules; The mechanical actuator comprises a drive motor, a winding component driven by the drive motor, and a control cable connected between the winding component and the throttle lever and the flameout lever of the diesel engine; The first set of signal acquisition modules are used to acquire the operating parameters of the diesel engine and transmit them to the first MCU; The first MCU is configured to: according to the received control instructions or operating parameters, control the operation of the drive motor, and then through the winding component, wind or unwind the control cable, to realize throttle control and flameout control of the diesel engine; The generator control device comprises a second MCU, a second set of signal acquisition modules and an actuator; The second group of signal acquisition modules are configured to acquire power parameters of the generator and transmit the power parameters to the second MCU; The second MCU is configured to control the actuator according to the power parameters to adjust the output of the generator. The diesel engine control device and the generator control device are interconnected through an internal communication bus. The intelligent terminal is communicatively connected with the diesel engine control device and / or the generator control device to receive state data and send control instructions.

[0005] Further, the mechanical actuator further comprises a limit switch arranged on the rotation path of the winding component, and the limit switch is configured to cut off the power supply circuit of the driving motor when the winding component rotates to the limit position.

[0006] Further, the winding component is a wheel disc or a roller, and the control cable is a flexible shaft or a cable.

[0007] Further, the internal communication bus is a CAN bus, an RS485 bus or a communication bus adopting a Modbus protocol or an MQTT protocol.

[0008] Further, the first group of signal acquisition modules comprises one or more of a water temperature acquisition module, an oil pressure acquisition module and a battery voltage acquisition module; the second group of signal acquisition modules comprises one or more of a voltage acquisition module, a current acquisition module and a frequency acquisition module; and the actuator is a silicon controlled relay or a contactor.

[0009] A cooperative control method based on the above intelligent control assembly, comprising: The generator control device acquires the output frequency of the generator in real time. When the output frequency deviates from the rated value, the generator control device sends a frequency adjustment signal to the diesel engine control device through the internal communication bus. The diesel engine control device receives the frequency adjustment signal and controls the mechanical actuator to act, and correspondingly adjusts the engine throttle opening to make the output frequency return to the rated value.

[0010] A diesel generator set comprising a diesel engine, a generator and the above intelligent control assembly.

[0011] A computer readable storage medium having a computer program stored thereon, the program being executed by a processor to implement the steps of the above method.

[0012] (Three) beneficial effects Compared with the prior art, the present application has the following advantages: Extremely low cost: The innovative use of a mechanical structure of "motor-winding component-control cable" to replace the expensive dedicated electronic speed controller (ECU), combined with a general-purpose MCU and standard sensors, reduces the overall cost by more than 70% year-on-year, solving the problem of difficulty in promoting high-end solutions.

[0013] Extremely high reliability: The mechanical actuator has a simple structure and its resistance to electromagnetic interference far surpasses that of purely electronic circuits. The limit switch provides physical-level safety protection, directly eliminating serious accidents such as engine "runaway" or "stalling" caused by MCU program malfunctions or crashes at the circuit level, fundamentally improving safety.

[0014] Excellent compatibility: This invention does not rely on specific electronic interfaces of the engine. It achieves control through a purely physical cable connection method. Without modifying the engine itself, it can be adapted to almost all models of traditional diesel engines for intelligent transformation, and has broad market application prospects.

[0015] Easy maintenance: The modular design allows for the independent replacement of standard components such as motors, MCUs, and signal acquisition modules. Faults can be quickly located and replaced individually, resulting in extremely low maintenance costs.

[0016] Fully functional: While achieving low cost and high reliability, it fully realizes advanced intelligent functions such as status monitoring, local / remote control, and automatic frequency adjustment through internal bus collaboration and intelligent terminals. Attached Figure Description

[0017] Figure 1 This is a system structure principle block diagram of the assembly of the present invention.

[0018] Figure 2 This is a schematic diagram of the hardware structure of the diesel engine control device in this invention.

[0019] Figure 3 This is a schematic diagram of the hardware structure of the generator control device in this invention.

[0020] Figure 4 This is a flowchart of the automatic frequency adjustment method of the present invention. Detailed Implementation

[0021] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. This description is for illustrative purposes only and is not intended to limit the scope of the invention.

[0022] like Figures 1 to 3 As shown, the present invention provides an intelligent control assembly for a diesel generator set, which mainly consists of three parts: a diesel engine control device (100), a generator control device (200), and an intelligent terminal (300). The intelligent terminal (300) can be a smartphone, tablet computer, or PC with a dedicated APP installed.

[0023] Referring to Figure 2 , the core of the diesel engine control device is a mechanical actuator controlled by a first MCU (101). A wheel disc (103) is fixedly installed on the output shaft of a DC speed reduction motor (102) as a winding component. One end of the throttle control line (104) and the flameout control line (105) is wound on the wheel disc, and the other end is connected to the throttle pull rod and the flameout pull rod of the diesel engine, respectively. The first MCU (101) controls a relay (106) to drive the motor (102) to rotate forward or reverse according to the control logic or instructions, so as to tighten or loosen the pull line, and realize the mechanical control of the diesel engine.

[0024] The key safety design of the application is that the limit switch (107) is precisely set at the limit position of the rotation of the wheel disc (103). Its signal line is directly connected in series in the power supply circuit of the driving motor (102). This means that once the wheel disc rotates and touches the limit switch (107), no matter what signal the first MCU (101) outputs, the power supply circuit of the motor will be physically cut off, and the motor will immediately stop rotating. This constitutes an absolutely reliable hardware safety redundancy independent of the software system, which fundamentally avoids the "runaway" accident caused by program runaway. At the same time, the first group of signal acquisition modules such as the water temperature acquisition module (108), the oil pressure acquisition module (109), and the battery voltage acquisition module (110) monitor the engine state in real time.

[0025] Referring to Figure 3 , the generator control device has a second MCU (201) as the core. The second group of signal acquisition modules (202) acquire parameters such as voltage, current, and frequency of the generator in real time. The output of the second MCU (201) controls the generator through an actuator such as a silicon controlled relay (SSR) (203) (such as excitation regulation).

[0026] Referring to Figure 1 , the communication bus (400) can be preferably a CAN bus to meet the internal coordination requirements of high real-time and high reliability. In addition, RS485 bus (running Modbus RTU protocol) or directly using Modbus TCP / IP over Ethernet can also be selected according to the cost and application scene. If the design goal focuses on cloud native architecture, MQTT protocol can also be selected as the carrier of internal data exchange.

[0027] Referring to Figure 4 , the frequency automatic regulation process of the cooperative control method is as follows: S101: The generator control device monitors the generator output frequency in real time.

[0028] S102: Determine whether the frequency deviates from the set value (such as 49.5 Hz). If yes, execute S103; if no, continue monitoring.

[0029] S103: The generator control device generates a frequency adjustment signal.

[0030] S104: Send to the diesel engine control device through the RS485 bus.

[0031] S105: After receiving the signal, the diesel engine control device drives the motor (102) to rotate, drives the throttle control line (104), and adjusts the throttle opening.

[0032] S106: The engine speed changes accordingly, the generator frequency rises to the normal range, and the automatic adjustment is completed.

[0033] The intelligent terminal establishes a connection with the two control devices through Wi-Fi or 4G network, and provides an interface for remote monitoring, data query and manual operation for the user.

[0034] The computer readable storage medium (such as FLASH chip) has a program stored thereon, which can realize the above-mentioned frequency automatic adjustment method when executed by the MCU.

[0035] Although the present application has been disclosed as above with the preferred embodiments, it is not intended to limit the present application. Any skilled person in the art can make many possible changes and modifications to the technical solutions of the present application, or modify equivalent embodiments with equivalent changes, without departing from the scope of the technical solutions of the present application. Therefore, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present application, without departing from the content of the technical solutions of the present application, still belongs to the scope of protection of the technical solutions of the present application.

Claims

1. An intelligent control assembly for a diesel generator set, characterized by, The diesel engine control device, the generator control device and at least one intelligent terminal are included. The diesel engine control device includes a first MCU, a mechanical actuator and a first group of signal acquisition modules. The mechanical actuator includes a driving motor, a winding component driven by the driving motor and a control cable connected between the winding component and the diesel engine throttle and the flameout lever. The first group of signal acquisition modules are used to acquire the operating parameters of the diesel engine and transmit them to the first MCU. The first MCU is configured to control the operation of the driving motor according to the received control instructions or operating parameters, and then control the winding and unwinding of the control cable through the winding component to realize the throttle and flameout control of the diesel engine. The generator control device includes a second MCU, a second group of signal acquisition modules and an actuator. The second group of signal acquisition modules are used to acquire the power parameters of the generator and transmit them to the second MCU. The second MCU is configured to control the actuator according to the power parameters to adjust the output of the generator. The diesel engine control device and the generator control device are interconnected through an internal communication bus. The intelligent terminal is communicatively connected with the diesel engine control device and / or the generator control device to receive state data and send control instructions. The mechanical actuator further includes a limit switch arranged on the rotation path of the winding component, which is configured to cut off the power supply circuit of the driving motor when the winding component rotates to the limit position.

2. The intelligent control assembly for a diesel generator set of claim 1, wherein, The winding component is a wheel disc or a roller, and the control cable is a soft shaft or a cable.

3. The intelligent control assembly for a diesel generator set of claim 2, wherein, The internal communication bus is a CAN bus, an RS485 bus or a communication bus using Modbus protocol or MQTT protocol.

4. The intelligent control assembly for a diesel generator set of claim 1, wherein, 5. The first group of signal acquisition modules according to claim 1 include one or more of a water temperature acquisition module, an oil pressure acquisition module and a battery voltage acquisition module; the second group of signal acquisition modules include one or more of a voltage acquisition module, a current acquisition module and a frequency acquisition module; and the actuator is a thyristor or a contactor. The generator control device acquires the output frequency of the generator in real time.

6. A method for cooperative control based on the intelligent control assembly according to any one of claims 1-4, characterized in that, When the output frequency deviates from the rated value, the generator control device sends a frequency adjustment signal to the diesel engine control device through the internal communication bus. The diesel engine control device receives the frequency adjustment signal and controls the mechanical actuator to adjust the engine throttle opening accordingly to make the output frequency return to the rated value. The diesel engine, the generator and the intelligent control assembly according to any one of claims 1-4 are included. The program is executed by the processor to implement the steps of the method according to claim 5.

7. A diesel generator set characterized by, ​ 8. A computer readable storage medium having stored thereon a computer program, characterized in that, ​

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