Steady-state load torque testing device and method for rotary fuel metering device

Abstract

The invention provides a steady-state load torque testing device and method for a rotary fuel metering device. The device comprises a permanent magnet servo motor, an operation control unit, a rotary transformer coding and decoding module, a rotor position signal conditioning module, a power inversion unit, a motor phase current monitoring module, a vector control module, a servo control algorithm module, a coupler, a metering valve and a valve driving system steady state torque identification module. A metering device steady state load moment online identification module; and an upper computer module.

Description

Technical Field

[0001] This invention belongs to the field of aero-engine control, specifically relating to a steady-state load torque testing device and method for a rotary fuel metering device. Background Technology

[0002] Fuel metering devices are key components of aero-engine control systems, crucial to engine control performance and reliability. The load torque of rotary fuel metering valves is affected by factors such as frictional resistance between the valve and bushing, hydraulic forces, and fuel cleanliness. Current measurements are only conducted using a tension gauge under conditions where the valve is offline, hydraulic forces are absent, and contaminants are stuck. This makes it difficult to accurately assess the impact of hydraulic forces and fuel cleanliness on the load torque, and the actual operating torque of the valve is difficult to measure. This hinders the assessment of whether the drive unit meets the requirements of the metering valve and also makes it difficult to evaluate the quality of the valve's manufacturing and assembly. Summary of the Invention

[0003] This invention proposes a steady-state load torque testing device and method for rotary fuel metering devices, which can solve the problem of difficulty in evaluating the quality of valve processing and assembly.

[0004] In a first aspect, this application provides a steady-state load torque testing device for a rotary fuel metering device, comprising: a permanent magnet servo motor, a computational control unit, a rotary transformer encoding / decoding module, a rotor position signal conditioning module, a power inverter unit, a motor phase current monitoring module, a vector control module, a servo control algorithm module, a coupling, a metering valve, a valve drive system steady-state torque identification module, a metering device steady-state load torque online identification module, and a host computer module, wherein: The permanent magnet servo motor is connected to the power inverter unit, rotor position signal conditioning module, motor phase current monitoring module, and coupling, respectively. The computing and control unit is connected to the host computer, rotary transformer encoding and decoding module, power inverter unit, motor phase current monitoring module, and valve drive system steady-state torque identification module, respectively. The rotary transformer encoding and decoding module is connected to the rotor position signal conditioning module and computing and control unit, respectively. The rotor position signal conditioning module is connected to the permanent magnet servo motor and rotary transformer encoding and decoding module, respectively. The power inverter unit is connected to the computing and control unit and permanent magnet servo motor, respectively. The motor phase current monitoring module is connected to the permanent magnet servo motor and computing and control unit, respectively. The coupling is connected to the permanent magnet servo motor and metering valve, respectively. The metering valve is connected to the coupling, and the valve drive system steady-state torque identification module is connected to the computing and control unit and the metering device steady-state load torque online identification module, respectively. The host computer module is connected to the computing and control unit.

[0005] Furthermore, the permanent magnet servo motor is used to drive the rotary metering valve to move through the coupling under control, thereby realizing fuel flow regulation, and at the same time feeding back the motor phase current to the current sensor and the motor rotor position to the signal conditioning module. The computation and control unit is the core of the device's computation and control, and serves as the carrier for implementing vector control and servo control algorithms. It also outputs PWM signals, which are converted into power signals by the power inverter unit and output to the motor windings. The rotary transformer encoding / decoding module is used to generate a rotary transformer excitation signal, output it to the rotor position signal conditioning module, receive the feedback signal output by the rotor position signal conditioning module, and calculate the motor rotor position based on the phase relationship between the excitation signal and the feedback signal. The rotor position signal conditioning module is used to receive the excitation signal from the rotary transformer encoding and decoding module, condition the signal and output it to the rotary transformer, and receive the feedback signal from the rotary transformer, condition it and output it to the rotary transformer encoding and decoding module. The power inverter unit is used to convert the control PWM signal output by the computing and control unit into a power PWM signal, thereby driving the permanent magnet servo motor to move. The motor phase current monitoring module is used to monitor the phase current of the three-phase windings of the motor and convert the current signal into a voltage signal suitable for microprocessor sampling. The vector control module is used to output a PWM signal based on the motor rotor position and motor phase current, combined with the servo control algorithm module. The servo control algorithm module is used to complete the closed-loop control of the motor rotor position, speed, and current. The coupling is used to connect the motor shaft and the metering valve shaft so that the two rotate synchronously; The metering valve is optional and driven by an electric motor to control fuel flow. The steady-state torque identification module of the valve drive system is used to identify the steady-state torque when the motor and the coupling move together; The valve steady-state torque identification module is used to identify the steady-state torque of the metering valve, including the load torque of the valve caused by the combined force of factors such as friction between the valve and the bushing, hydraulic force, and fuel cleanliness. The host computer module is used to interact with the computing and control unit, send motion commands to the device, and visualize the measurement results of the measuring device.

[0006] Furthermore, the arithmetic control unit includes a high-speed AD converter, an arithmetic control unit, a logic unit, a data storage unit, and a program storage unit. The arithmetic control unit monitors the motor rotor position in real time and receives angle servo commands from the host computer. It transmits the angle commands and the electronic rotor position to the servo control algorithm module. The servo algorithm module and the vector control module cooperate to realize angle servoing. The vector control module outputs the PWM duty cycle command to the arithmetic control unit, which controls the six-channel complementary duty cycle output.

[0007] Furthermore, the rotor position signal conditioning module includes: a resolver excitation signal conditioner and a resolver output signal conditioner, wherein: The rotary transformer encoding / decoding module amplifies the output sinusoidal signal with high bandwidth, increasing the peak-to-peak value to 12V. The rotary transformer excitation signal conditioner consists of an active filter bias circuit and a voltage amplifier circuit connected in series. The active filter bias circuit superimposes the 2V sinusoidal signal output from the rotary transformer excitation signal generator with a 2.5V DC bias signal, and then performs a second-order active Chebyshev filter on the signal. The filter parameters are adjusted by resistors and capacitors. The output signal conditioner of the rotary transformer consists of an electrostatic discharge (ESD) protector, an active filter, and a signal amplifier connected in series. The ESD protector is used to prevent damage to the subsequent circuitry caused by static electricity from the human body during the insertion and removal of the rotary transformer's electrical connector. The active filter is a second-order active Chebyshev filter with DC bias function, and its parameter configuration is consistent with that of the excitation signal conditioner. The signal amplifier is used to condition the signal output from the rotary transformer into a sine differential and cosine differential signal with a peak value of 3.2V.

[0008] Furthermore, the motor phase current monitoring module includes: a Hall current sensor, a signal conditioner, and a current measuring device connected in sequence, wherein: The primary terminal of the Hall current sensor is connected in series in each phase line of the motor. When the motor phase current flows through the Hall sensor, the secondary terminal of the sensor will sense the corresponding voltage, realizing the I / V conversion from current to voltage. The signal conditioner is a voltage follower connected in series with an RC low-pass filter. The voltage signal output by the current sensor is connected to the non-inverting input of the follower, the inverting input of the follower is connected to the output, and the output of the follower is connected to the RC filter. The current measuring device samples the voltage value after RC filtering, and combines the correspondence between the current and output voltage of the Hall current sensor to calculate the motor phase current in reverse from the voltage value.

[0009] Furthermore, the vector control module includes a Clark transform module, a Park transform module, an inverse Park transform module, and an SVPWM vector calculation module, wherein: The Clark transformation module, based on the principle of amplitude equivalence, transforms the three-phase AC current into two-phase currents iα and iβ in a stationary coordinate system. The Park transformation integrates iα, iβ, and the motor rotor position θ to calculate the direct-axis current id and quadrature-axis current iq in the rotating coordinate system. The inverse Park transformation receives the direct-axis voltage Ud, quadrature-axis voltage Uq, and motor rotor position θ output by the servo control algorithm module, and converts the voltages in the two-phase rotating coordinate system into voltages Uα and Uβ in the two-phase stationary coordinate system. The SVPWM vector calculation module performs sector analysis, vector calculation, and correction based on Uα and Uβ, and outputs 6-channel PWM.

[0010] Furthermore, the servo control algorithm module includes: position control algorithm, speed control algorithm, direct-axis current id control algorithm, and quadrature-axis current iq control algorithm, wherein: The position control algorithm receives the position command sent by the host computer, calculates the deviation between the actual measured rotor position and the position command, and implements closed-loop control. The controller is a P controller. The position control algorithm outputs the speed command to the speed control algorithm. The speed control algorithm receives the speed command output by the position loop and calculates the deviation between the actual speed calculated after the motor rotor position is differentiated. The speed controller implements closed-loop speed control, and the speed controller is a PI controller. The speed loop outputs the quadrature-axis current command iq. The quadrature axis current iq control algorithm receives the quadrature axis current command output by the speed loop, and calculates the deviation with the iq current feedback output by the vector control module. The iq current controller performs closed-loop control and outputs voltage uq to the vector control module. The iq current controller is a PI controller. The direct-axis current id control algorithm, where the id current command is 0, is fed back to the iq current output by the vector control module to calculate the deviation. The iq current controller performs closed-loop control and outputs voltage uq to the vector control module. The iq current controller is a PI controller.

[0011] Furthermore, the steady-state torque identification module of the valve drive system includes: control plan generation, control plan execution, motor constant speed state identification, and steady-state torque identification, wherein: The control plan generation method is used to plan the initial position, ending position, acceleration segment, constant speed segment, deceleration segment, acceleration time, constant speed time, and deceleration time of the motor. The control plan execution method is as follows: the operation and control unit receives the parameters issued by the control plan and first controls the motor to run to the initial position; After the motor reaches the initial position, the acceleration is calculated based on the acceleration segment and acceleration time. A series of speed commands are generated based on the acceleration and sent to the motor speed control loop. Once the motor reaches the final acceleration speed, a constant speed command is issued, and the motor rotor position is monitored in real time. After the constant speed segment ends, based on the acceleration and deceleration time of the deceleration segment, a series of speed commands for the deceleration segment are generated and sent to the speed loop. During the constant speed range of the motor, the quadrature-axis current iq is monitored in real time; The method for identifying the uniform speed state of the motor is as follows: after the acceleration phase ends, the uniform speed phase speed command is executed, the calculation control unit monitors the motor speed in real time, and records the current motor speed as n(k), the next motor speed as n(k+1), and the next-next motor speed as n(k+2). Define acceleration a(k) = (n(k+1) - n(k)) / ΔT, a(k+1) = (n(k+2) - n(k+1)) / ΔT; if |a(k+1) - a(k)| < ε, then the motor is considered to be in a uniform speed state, and the quadrature-axis current iq1 corresponding to this state is recorded; otherwise, the motor is in a non-uniform speed state; ΔT is the speed sampling period. The steady-state torque identification method is as follows: T1 = 1.5 * KT * iq1, where T1 is the current electromagnetic torque and KT is the motor torque coefficient.

[0012] Furthermore, the online steady-state load torque identification module for the metering device includes: online operation testing of the metering device, system steady-state torque testing, and calculation of the steady-state load torque of the metering device, wherein: The online operation test of the metering device is as follows: the motor and the metering valve are connected by a coupling, so that the motor drives the metering valve to rotate. The metering device works in the actual operating state. When the motor is adjusted to different positions, the fuel flow rate changes with the valve position. Then the online operation test of the metering device is completed. The system steady-state torque test method is as follows: repeat the identification content of the steady-state torque identification module of the valve drive system, but after the motor is connected to the metering valve, the steady-state torque changes, and the calculated steady-state torque is recorded as T2; The method for calculating the steady-state load torque of the metering device is as follows: the steady-state load torque of the metering device in a single test is denoted as T = T2 - T1. The test is repeated ten times, and the average of the results of the ten tests is taken. This average value is the steady-state load torque of the metering device.

[0013] Secondly, this application provides a method for testing the steady-state load torque of a rotary fuel metering device. The method is applied to the aforementioned rotary fuel metering device steady-state load torque testing device, and includes: Step 1: Determine the control plan parameters, including the initial position, final position, acceleration phase, constant speed phase, deceleration phase, acceleration time, constant speed time, and deceleration time of the motor; Step 2: The arithmetic control unit executes the control plan according to the control plan parameters; first, it controls the motor to run to the initial position; after the motor reaches the initial position, it calculates the acceleration according to the acceleration segment and acceleration time, generates a series of speed commands based on the acceleration, and sends the speed commands to the motor speed control loop; when the motor reaches the speed at the end of the acceleration segment, it sends a constant speed command and monitors the motor rotor position in real time. Step 3: Determine if the motor is in a uniform speed state, including: let the current motor speed be n(k), the next motor speed be n(k+1), and the next-next motor speed be n(k+2); define acceleration a(k) = (n(k+1) - n(k)) / ΔT, a(k+1) = (n(k+2) - n(k+1)) / ΔT; if |a(k+1) - a(k)| < ε, then the motor is considered to be in a uniform speed state, record the quadrature-axis current iq1 corresponding to this state, and proceed to step 4; otherwise, the motor is in a non-uniform speed state, where ΔT is the speed sampling period; Step 4: Calculate the no-load torque T1 of the motor according to the algorithm T1=1.5*KT* iq1, where KT is the motor torque coefficient; Step 5: Online operation test of motor-driven metering valve, specifically including: connecting the motor and metering valve through a coupling, so that the motor drives the metering valve to rotate, and the metering device works in actual operation state; when the motor is adjusted to different positions, the fuel flow rate changes with the valve position, then the online operation test of motor-driven metering valve is completed, and proceed to step 6; Step 6: Steady-state torque test of motor and metering valve, specifically including: repeating steps 1 to 4, measuring the motor cross-axis current iq2 when the motor and metering valve move at a constant speed; calculating the current steady-state electromagnetic torque T2 according to the algorithm T2=1.5*KT* iq2, where KT is the motor torque coefficient; Step 7: Calculate the steady-state load torque of the metering device, which includes: recording the steady-state load torque of the metering device in a single test as T = T2 - T1; repeating steps 1 to 6 ten times, recording the test result T for each test, and averaging the results of the ten tests. This average value is the steady-state load torque of the metering device.

[0014] In summary, this application proposes a test device and method for steady-state load torque of a rotary fuel metering device; it clarifies the steady-state torque of the fuel metering device, providing feedback basis for the design and theoretical analysis of the metering device; it provides a basis for fault diagnosis and health management of the metering device; and it lays the foundation for the safe and reliable control of aero-engine operation. Attached Figure Description

[0015] Figure 1 A schematic diagram of the structure of a steady-state load torque testing device for a rotary fuel metering device provided in this application; Figure 2 A schematic diagram of a rotary transformer excitation signal conditioner provided in this application; Figure 3 A schematic diagram of a rotary transformer output signal conditioner provided in this application; Figure 4 A schematic diagram of a power inverter unit provided in this application; Figure 5 A schematic diagram of a vector control module provided in this application; Figure 6 A schematic diagram of a servo control algorithm module provided in this application. Detailed Implementation

[0016] Example 1 like Figure 1 As shown, this application provides a steady-state load torque testing device for a rotary fuel metering device, comprising: a permanent magnet servo motor, a computational control unit, a rotary transformer encoding / decoding module, a rotor position signal conditioning module, a power inverter unit, a motor phase current monitoring module, a vector control module, a servo control algorithm module, a coupling, a metering valve, a valve drive system steady-state torque identification module, a metering device steady-state load torque online identification module, and a host computer module, wherein: The permanent magnet servo motor is connected to the power inverter unit, rotor position signal conditioning module, motor phase current monitoring module, and coupling, respectively. The computing and control unit is connected to the host computer, rotary transformer encoding and decoding module, power inverter unit, motor phase current monitoring module, and valve drive system steady-state torque identification module, respectively. The rotary transformer encoding and decoding module is connected to the rotor position signal conditioning module and computing and control unit, respectively. The rotor position signal conditioning module is connected to the permanent magnet servo motor and rotary transformer encoding and decoding module, respectively. The power inverter unit is connected to the computing and control unit and permanent magnet servo motor, respectively. The motor phase current monitoring module is connected to the permanent magnet servo motor and computing and control unit, respectively. The coupling is connected to the permanent magnet servo motor and metering valve, respectively. The metering valve is connected to the coupling, and the valve drive system steady-state torque identification module is connected to the computing and control unit and the metering device steady-state load torque online identification module, respectively. The host computer module is connected to the computing and control unit.

[0017] The permanent magnet servo motor is used to drive the rotary metering valve to move through the coupling under control to achieve fuel flow regulation. At the same time, it feeds back the motor phase current to the current sensor and the motor rotor position to the signal conditioning module. The computation and control unit is the core of the device's computation and control, and serves as the carrier for implementing vector control and servo control algorithms. It also outputs PWM signals, which are converted into power signals by the power inverter unit and output to the motor windings. The rotary transformer encoding / decoding module is used to generate a rotary transformer excitation signal, output it to the rotor position signal conditioning module, receive the feedback signal output by the rotor position signal conditioning module, and calculate the motor rotor position based on the phase relationship between the excitation signal and the feedback signal. The rotor position signal conditioning module is used to receive the excitation signal from the rotary transformer encoding and decoding module, condition the signal and output it to the rotary transformer, and receive the feedback signal from the rotary transformer, condition it and output it to the rotary transformer encoding and decoding module. The power inverter unit is used to convert the control PWM signal output by the computing and control unit into a power PWM signal, thereby driving the permanent magnet servo motor to move. The motor phase current monitoring module is used to monitor the phase current of the three-phase windings of the motor and convert the current signal into a voltage signal suitable for microprocessor sampling. The vector control module is used to output a PWM signal based on the motor rotor position and motor phase current, combined with the servo control algorithm module. The servo control algorithm module is used to complete the closed-loop control of the motor rotor position, speed, and current. The coupling is used to connect the motor shaft and the metering valve shaft so that the two rotate synchronously; The metering valve is optional and driven by an electric motor to control fuel flow. The steady-state torque identification module of the valve drive system is used to identify the steady-state torque when the motor and the coupling move together; The valve steady-state torque identification module is used to identify the steady-state torque of the metering valve, including the load torque of the valve caused by the combined force of factors such as friction between the valve and the bushing, hydraulic force, and fuel cleanliness. The host computer module is used to interact with the computing and control unit, send motion commands to the device, and visualize the measurement results of the measuring device.

[0018] Specifically, when the test device is in operation, it is deployed on a ground platform, and the system is pressurized by a fuel pump to provide the fuel pressure and hydraulic power required for the rotary fuel metering device to operate.

[0019] Specifically, the permanent magnet servo motor is installed with fixed fixtures to ensure reliable support of the motor, and the motor shaft is concentric with the valve shaft. After the motor and the metering valve are connected by a coupling, the motor is almost unaffected by radial force during movement.

[0020] The permanent magnet servo motor includes three-phase windings A, B, and C, and integrates a rotary transformer for rotor position measurement. The rotor of the rotary transformer is coaxial with the motor rotor, and the zero point of the rotary transformer is aligned with the zero-crossing point of the opposite potential of motor A. Specifically, the arithmetic control unit is the core of the arithmetic control of the measuring device. It contains a high-speed AD converter, arithmetic control unit, logic unit, data storage unit, program storage unit, etc. The computation control unit monitors the motor rotor position in real time and receives angle servo commands from the host computer. It transmits the angle commands and electronic rotor position to the servo control algorithm module. The servo algorithm module and the vector control module cooperate to realize angle servoing. The vector control module outputs the PWM duty cycle command to the computation control unit, which controls the six-channel complementary duty cycle output.

[0021] Specifically, the rotary transformer encoding / decoding module generates a sinusoidal excitation signal; receives sinusoidal differential and cosine differential signals output by the rotor position signal conditioning module; calculates the rotor position using its internal position calculation algorithm; and outputs the calculation result to the arithmetic control unit via a parallel bus.

[0022] The rotary transformer encoding / decoding module generates a sinusoidal excitation signal with an output frequency of 10kHz, an amplitude of 2V, and a DC bias of 2.5V. The rotor position signal conditioning module outputs sinusoidal differential and cosine differential signals with a DC bias of 2.5V and a peak value of 3.2V.

[0023] Specifically, the rotor position signal conditioning module includes: a rotary transformer excitation signal conditioner and a rotary transformer output signal conditioner; like Figure 2 As shown, the resolver encoding / decoding module amplifies the output sinusoidal signal with high bandwidth, increasing the peak-to-peak value to 12V. The resolver excitation signal conditioner consists of an active filter bias circuit and a voltage amplifier circuit connected in series. The active filter bias circuit superimposes the 2V sinusoidal signal output from the resolver excitation signal generator with a 2.5V DC bias signal, and then performs a second-order active Chebyshev filter on the signal. The filter parameters are adjusted by resistors and capacitors.

[0024] The filter stopband attenuation is configured to -20dB, and the cutoff frequency is configured to 18KHz.

[0025] like Figure 3As shown, the output signal conditioner of the rotary transformer consists of an electrostatic discharge (ESD) protector, an active filter, and a signal amplifier connected in series. The ESD protector is used to prevent damage to the subsequent circuitry caused by static electricity from the human body during the insertion and removal of the rotary transformer's electrical connector. The active filter is a second-order active Chebyshev filter with DC bias function, and its parameter configuration is consistent with that of the excitation signal conditioner. The signal amplifier is used to condition the 2.6V peak value signal output by the rotary transformer into a 3.2V peak value sine differential and cosine differential signal.

[0026] Specifically, such as Figure 4 As shown, the power inverter unit includes a gate driver and a power inverter unit connected in sequence; The gate driver receives the TTL signal output by the operational control unit and converts it into a signal with a strong drive current of 15V required for each MOS transistor of the power inverter unit to operate. The power inverter unit receives the control signal from the gate driver and, under the control of the gate driver, realizes the switching of the MOS transistor; the gate driver and the power inverter unit work together to realize the conversion of TTL signal to power signal.

[0027] Specifically, the motor phase current monitoring module includes: a Hall current sensor, a signal conditioner, and a current measuring device connected in sequence.

[0028] The primary terminal of the Hall current sensor is connected in series in each phase line of the motor. When the motor phase current flows through the Hall sensor, the secondary terminal of the sensor will sense the corresponding voltage, realizing the I / V conversion from current to voltage. The signal conditioner is a voltage follower connected in series with an RC low-pass filter. The voltage signal output by the current sensor is connected to the non-inverting input of the follower, the inverting input of the follower is connected to the output, and the output of the follower is connected to the RC filter. The filter bandwidth is set to 40kHz. The current measuring device samples the voltage value after RC filtering, and combines the correspondence between the current and output voltage of the Hall current sensor to calculate the motor phase current in reverse from the voltage value.

[0029] The current measuring device periodically samples the voltage value after RC filtering at a frequency of 10KHz.

[0030] Specifically, such as Figure 5 As shown, the vector control module includes a Clark transform module, a Park transform module, an inverse Park transform module, and an SVPWM vector calculation module; The Clark transformation module, based on the principle of amplitude equivalence, transforms the three-phase AC current into two-phase currents iα and iβ in a stationary coordinate system. The Park transformation integrates iα, iβ, and the motor rotor position θ to calculate the direct-axis current id and quadrature-axis current iq in the rotating coordinate system. The inverse Park transformation receives the direct-axis voltage Ud, quadrature-axis voltage Uq, and motor rotor position θ output by the servo control algorithm module, and converts the voltages in the two-phase rotating coordinate system into voltages Uα and Uβ in the two-phase stationary coordinate system. The SVPWM vector calculation module performs sector analysis, vector calculation, and correction based on Uα and Uβ, and outputs 6-channel PWM.

[0031] Specifically, such as Figure 6 As shown, the servo control algorithm module includes: position control algorithm, speed control algorithm, direct axis current id control algorithm, and quadrature axis current iq control algorithm; The position control algorithm receives the position command sent by the host computer, calculates the deviation between the actual measured rotor position and the position command, and implements closed-loop control. The controller is a P controller. The position control algorithm outputs the speed command to the speed control algorithm. The speed control algorithm receives the speed command output by the position loop and calculates the deviation between the actual speed calculated after the motor rotor position is differentiated. The speed controller implements closed-loop speed control, and the speed controller is a PI controller. The speed loop outputs the quadrature-axis current command iq. The quadrature axis current iq control algorithm receives the quadrature axis current command output by the speed loop, and calculates the deviation with the iq current feedback output by the vector control module. The iq current controller performs closed-loop control and outputs voltage uq to the vector control module. The iq current controller is a PI controller. The direct-axis current id control algorithm, where the id current command is 0, is fed back to the iq current output by the vector control module to calculate the deviation. The iq current controller performs closed-loop control and outputs voltage uq to the vector control module. The iq current controller is a PI controller. Specifically, the steady-state torque identification module of the valve drive system includes: control plan generation, control plan execution, motor constant speed state identification, and steady-state torque identification.

[0032] The control plan generation method is used to plan the initial position, ending position, acceleration segment, constant speed segment, deceleration segment, acceleration time, constant speed time, and deceleration time of the motor. The control plan execution method is as follows: the operation and control unit receives the parameters issued by the control plan and first controls the motor to run to the initial position; After the motor reaches the initial position, the acceleration is calculated based on the acceleration segment and acceleration time. A series of speed commands are generated based on the acceleration and sent to the motor speed control loop. Once the motor reaches the final acceleration speed, a constant speed command is issued, and the motor rotor position is monitored in real time. After the constant speed segment ends, based on the acceleration and deceleration time of the deceleration segment, a series of speed commands for the deceleration segment are generated and sent to the speed loop. During the constant speed range of the motor, the quadrature-axis current iq is monitored in real time; The method for identifying the uniform speed state of the motor is as follows: after the acceleration phase ends, the uniform speed phase speed command is executed, the calculation control unit monitors the motor speed in real time, and records the current motor speed as n(k), the next motor speed as n(k+1), and the next-next motor speed as n(k+2). Define acceleration a(k) = (n(k+1) - n(k)) / ΔT, a(k+1) = (n(k+2) - n(k+1)) / ΔT; if |a(k+1) - a(k)| < ε, then the motor is considered to be in a uniform speed state, and the quadrature-axis current iq1 corresponding to this state is recorded; otherwise, the motor is in a non-uniform speed state. ΔT is the speed sampling period.

[0033] The steady-state torque identification method is as follows: T1 = 1.5 * KT * iq1, where T1 is the current electromagnetic torque and KT is the motor torque coefficient; Specifically, the online identification module for steady-state load torque of metering devices includes: online operation testing of metering devices, steady-state torque testing of the system, and calculation of steady-state load torque of metering devices.

[0034] The online operation test of the metering device is as follows: the motor and the metering valve are connected by a coupling, so that the motor drives the metering valve to rotate. The metering device works in the actual operating state. When the motor is adjusted to different positions, the fuel flow rate changes with the valve position. Then the online operation test of the metering device is completed. The system steady-state torque test method is as follows: repeat the identification content of the steady-state torque identification module of the valve drive system, but after the motor is connected to the metering valve, the steady-state torque changes, and the calculated steady-state torque is recorded as T2; The method for calculating the steady-state load torque of the metering device is as follows: the steady-state load torque of the metering device in a single test is denoted as T = T2 - T1. The test is repeated ten times, and the average of the results of the ten tests is taken. This average value is the steady-state load torque of the metering device.

[0035] In summary, this invention proposes a steady-state load torque testing device for a rotary fuel metering device. It measures the overall true load torque of the valve in real time online, taking into account factors such as valve friction, hydraulic force, and fuel contamination. This provides data reference for the design of rotary valves, clarifies the matching relationship between the valve and the actuator, and can also serve as an important basis for valve fault diagnosis and health management, laying the foundation for improving the control performance and operational safety of aero-engines.

[0036] Example 2 This invention proposes a method for testing the steady-state load torque of a rotary fuel metering device, comprising: Step 1: Control Plan Generation Specifically, step 1 includes: Step 11: Plan the initial position, ending position, acceleration phase, constant speed phase, and deceleration phase of the motor, as well as the acceleration time, constant speed time, and deceleration time; Step 2: Control the execution of the plan Specifically, step 2 includes: Step 21: The calculation and control unit receives the parameters issued by the control plan and first controls the motor to run to the initial position; Step 22: After the motor reaches the initial position, the acceleration is calculated based on the acceleration segment and acceleration time. A series of speed commands are generated based on the acceleration and sent to the motor speed control loop. Step 23: After the motor reaches the final acceleration speed, issue a constant speed command and monitor the motor rotor position in real time. Step 3: Identification of Uniform Motion State Specifically, step 3 includes: Step 31: Let the current motor speed be n(k), the next motor speed be n(k+1), and the next-next motor speed be n(k+2); Step 32: Define acceleration a(k) = (n(k+1) - n(k)) / ΔT, a(k+1) = (n(k+2) - n(k+1)) / ΔT; if |a(k+1) - a(k)| < ε, then the motor is considered to be in a uniform speed state, record the quadrature-axis current iq1 corresponding to this state, and proceed to step 4; otherwise, the motor is in a non-uniform speed state. ΔT is the speed sampling period.

[0037] Step 4: Calculate the motor's no-load torque Specifically, step 4 includes: Step 41: Calculate the no-load torque of the motor according to the algorithm T1=1.5*KT* iq1, where T1 is the current electromagnetic torque and KT is the motor torque coefficient; Step 5: Online operation test of motor-driven metering valve Specifically, step 5 includes: Step 51: Connect the motor and the metering valve through a coupling, so that the motor drives the metering valve to rotate, and the metering device works in the actual operating state; Step 52: When the motor is adjusted to different positions, the fuel flow rate changes with the valve position. Then the online operation test of the motor-driven metering valve is completed, and proceed to step 6. Step 6: Steady-state torque test of motor and metering valve Specifically, step 6 includes: Step 61: Repeat steps 1 to 4 to measure the cross-axis current iq2 of the motor when the motor and the metering valve move at a constant speed; Step 62: Calculate the no-load torque of the motor according to the algorithm T2=1.5*KT* iq2, where T2 is the current electromagnetic torque and KT is the motor torque coefficient; Step 7: Calculation of steady-state load torque of the metering device Specifically, step 7 includes: Step 71: Record the steady-state load torque of the metering device in a single test as T = T2 - T1; Step 72: Repeat steps 1 to 6 ten times, record the test result T for each test, and take the average of the ten test results. This average value is the steady-state load torque of the measuring device.

[0038] This invention is primarily used in aero-engine control systems. Its main function is to solve the problem of accurately measuring the load torque of a rotary fuel metering device during actual operation by designing an online load torque testing device. This provides data reference for the theoretical design and analysis of fuel metering devices, facilitating device design optimization; it also serves as a basis for fault diagnosis and health management of the metering device; and it lays the foundation for improving the control performance and operational safety of aero-engines.

Claims

1. A steady-state load torque testing device for a rotary fuel metering device, characterized in that, include: The system includes a permanent magnet servo motor, a computation and control unit, a rotary transformer encoding / decoding module, a rotor position signal conditioning module, a power inverter unit, a motor phase current monitoring module, a vector control module, a servo control algorithm module, a coupling, a metering valve, a valve drive system steady-state torque identification module, a metering device steady-state load torque online identification module, and a host computer module. The permanent magnet servo motor is connected to the power inverter unit, rotor position signal conditioning module, motor phase current monitoring module, and coupling, respectively. The computing and control unit is connected to the host computer, rotary transformer encoding and decoding module, power inverter unit, motor phase current monitoring module, and valve drive system steady-state torque identification module, respectively. The rotary transformer encoding and decoding module is connected to the rotor position signal conditioning module and computing and control unit, respectively. The rotor position signal conditioning module is connected to the permanent magnet servo motor and rotary transformer encoding and decoding module, respectively. The power inverter unit is connected to the computing and control unit and permanent magnet servo motor, respectively. The motor phase current monitoring module is connected to the permanent magnet servo motor and computing and control unit, respectively. The coupling is connected to the permanent magnet servo motor and metering valve, respectively. The metering valve is connected to the coupling, and the valve drive system steady-state torque identification module is connected to the computing and control unit and the metering device steady-state load torque online identification module, respectively. The host computer module is connected to the computing and control unit.

2. The apparatus according to claim 1, characterized in that, The permanent magnet servo motor is used to drive the rotary metering valve to move through the coupling under control to achieve fuel flow regulation. At the same time, it feeds back the motor phase current to the current sensor and the motor rotor position to the signal conditioning module. The computation and control unit is the core of the device's computation and control, and serves as the carrier for implementing vector control and servo control algorithms. It also outputs PWM signals, which are converted into power signals by the power inverter unit and output to the motor windings. The rotary transformer encoding / decoding module is used to generate a rotary transformer excitation signal, output it to the rotor position signal conditioning module, receive the feedback signal output by the rotor position signal conditioning module, and calculate the motor rotor position based on the phase relationship between the excitation signal and the feedback signal. The rotor position signal conditioning module is used to receive the excitation signal from the rotary transformer encoding and decoding module, condition the signal and output it to the rotary transformer, and receive the feedback signal from the rotary transformer, condition it and output it to the rotary transformer encoding and decoding module. The power inverter unit is used to convert the control PWM signal output by the computing and control unit into a power PWM signal, thereby driving the permanent magnet servo motor to move. The motor phase current monitoring module is used to monitor the phase current of the three-phase windings of the motor and convert the current signal into a voltage signal suitable for microprocessor sampling. The vector control module is used to output a PWM signal based on the motor rotor position and motor phase current, combined with the servo control algorithm module. The servo control algorithm module is used to complete the closed-loop control of the motor rotor position, speed, and current. The coupling is used to connect the motor shaft and the metering valve shaft so that the two rotate synchronously; The metering valve is optional and driven by an electric motor to control fuel flow. The steady-state torque identification module of the valve drive system is used to identify the steady-state torque when the motor and the coupling move together; The valve steady-state torque identification module is used to identify the steady-state torque of the metering valve, including the load torque of the valve caused by the combined force of factors such as friction between the valve and the bushing, hydraulic force, and fuel cleanliness. The host computer module is used to interact with the computing and control unit, send motion commands to the device, and visualize the measurement results of the measuring device.

3. The apparatus according to claim 1, characterized in that, The arithmetic control unit includes a high-speed AD converter, an arithmetic control unit, a logic unit, a data storage unit, and a program storage unit. The arithmetic control unit monitors the motor rotor position in real time and receives angle servo commands from the host computer. It transmits the angle commands and the electronic rotor position to the servo control algorithm module. The servo algorithm module and the vector control module cooperate to realize angle servoing. The vector control module outputs the PWM duty cycle command to the arithmetic control unit, which controls the six-channel complementary duty cycle output.

4. The apparatus according to claim 1, characterized in that, The rotor position signal conditioning module includes: a resolver excitation signal conditioner and a resolver output signal conditioner, wherein: The rotary transformer encoding / decoding module amplifies the output sinusoidal signal with high bandwidth, increasing the peak-to-peak value to 12V. The rotary transformer excitation signal conditioner consists of an active filter bias circuit and a voltage amplifier circuit connected in series. The active filter bias circuit superimposes the 2V sinusoidal signal output from the rotary transformer excitation signal generator with a 2.5V DC bias signal, and then performs a second-order active Chebyshev filter on the signal. The filter parameters are adjusted by resistors and capacitors. The output signal conditioner of the rotary transformer consists of an electrostatic discharge (ESD) protector, an active filter, and a signal amplifier connected in series. The ESD protector is used to prevent damage to the subsequent circuitry caused by static electricity from the human body during the insertion and removal of the rotary transformer's electrical connector. The active filter is a second-order active Chebyshev filter with DC bias function, and its parameter configuration is consistent with that of the excitation signal conditioner. The signal amplifier is used to condition the signal output from the rotary transformer into a sine differential and cosine differential signal with a peak value of 3.2V.

5. The apparatus according to claim 1, characterized in that, The motor phase current monitoring module includes: a Hall current sensor, a signal conditioner, and a current measuring device connected in sequence, wherein: The primary terminal of the Hall current sensor is connected in series in each phase line of the motor. When the motor phase current flows through the Hall sensor, the secondary terminal of the sensor will sense the corresponding voltage, realizing the I / V conversion from current to voltage. The signal conditioner is a voltage follower connected in series with an RC low-pass filter. The voltage signal output by the current sensor is connected to the non-inverting input of the follower, the inverting input of the follower is connected to the output, and the output of the follower is connected to the RC filter. The current measuring device samples the voltage value after RC filtering, and combines the correspondence between the current and output voltage of the Hall current sensor to calculate the motor phase current in reverse from the voltage value.

6. The apparatus according to claim 1, characterized in that, The vector control module includes a Clark transform module, a Park transform module, an inverse Park transform module, and an SVPWM vector calculation module, among which: The Clark transformation module, based on the principle of amplitude equivalence, transforms the three-phase AC current into two-phase currents iα and iβ in a stationary coordinate system. The Park transformation integrates iα, iβ, and the motor rotor position θ to calculate the direct-axis current id and quadrature-axis current iq in the rotating coordinate system. The inverse Park transformation receives the direct-axis voltage Ud, quadrature-axis voltage Uq, and motor rotor position θ output by the servo control algorithm module, and converts the voltages in the two-phase rotating coordinate system into voltages Uα and Uβ in the two-phase stationary coordinate system. The SVPWM vector calculation module performs sector analysis, vector calculation, and correction based on Uα and Uβ, and outputs 6-channel PWM.

7. The apparatus according to claim 1, characterized in that, The servo control algorithm module includes: position control algorithm, speed control algorithm, direct-axis current (id) control algorithm, and quadrature-axis current (iq) control algorithm, among which: The position control algorithm receives the position command sent by the host computer, calculates the deviation between the actual measured rotor position and the position command, and implements closed-loop control. The controller is a P controller. The position control algorithm outputs the speed command to the speed control algorithm. The speed control algorithm receives the speed command output by the position loop and calculates the deviation between the actual speed calculated after the motor rotor position is differentiated. The speed controller implements closed-loop speed control, and the speed controller is a PI controller. The speed loop outputs the quadrature-axis current command iq. The quadrature axis current iq control algorithm receives the quadrature axis current command output by the speed loop, and calculates the deviation with the iq current feedback output by the vector control module. The iq current controller performs closed-loop control and outputs voltage uq to the vector control module. The iq current controller is a PI controller. The direct-axis current id control algorithm, where the id current command is 0, is fed back to the iq current output by the vector control module to calculate the deviation. The iq current controller performs closed-loop control and outputs voltage uq to the vector control module. The iq current controller is a PI controller.

8. The apparatus according to claim 1, characterized in that, The steady-state torque identification module for the valve drive system includes: control plan generation, control plan execution, motor constant speed state identification, and steady-state torque identification, among which: The control plan generation method is used to plan the initial position, ending position, acceleration segment, constant speed segment, deceleration segment, acceleration time, constant speed time, and deceleration time of the motor. The control plan execution method is as follows: the operation and control unit receives the parameters issued by the control plan and first controls the motor to run to the initial position; After the motor reaches the initial position, the acceleration is calculated based on the acceleration segment and acceleration time. A series of speed commands are generated based on the acceleration and sent to the motor speed control loop. Once the motor reaches the final acceleration speed, a constant speed command is issued, and the motor rotor position is monitored in real time. After the constant speed segment ends, based on the acceleration and deceleration time of the deceleration segment, a series of speed commands for the deceleration segment are generated and sent to the speed loop. During the constant speed range of the motor, the quadrature-axis current iq is monitored in real time; The method for identifying the uniform speed state of the motor is as follows: after the acceleration phase ends, the uniform speed phase speed command is executed, the calculation control unit monitors the motor speed in real time, and records the current motor speed as n(k), the next motor speed as n(k+1), and the next-next motor speed as n(k+2). Define acceleration a(k) = (n(k+1) - n(k)) / ΔT, a(k+1) = (n(k+2) - n(k+1)) / ΔT; if |a(k+1) - a(k)| < ε, then the motor is considered to be in a uniform speed state, and the quadrature-axis current iq1 corresponding to this state is recorded; otherwise, the motor is in a non-uniform speed state; ΔT is the speed sampling period. The steady-state torque identification method is as follows: T1 = 1.5 * KT * iq1, where T1 is the current electromagnetic torque and KT is the motor torque coefficient.

9. The apparatus according to claim 1, characterized in that, The online steady-state load torque identification module for metering devices includes: online operation testing of the metering device, system steady-state torque testing, and calculation of the steady-state load torque of the metering device, wherein: The online operation test of the metering device is as follows: the motor and the metering valve are connected by a coupling, so that the motor drives the metering valve to rotate. The metering device works in the actual operating state. When the motor is adjusted to different positions, the fuel flow rate changes with the valve position. Then the online operation test of the metering device is completed. The system steady-state torque test method is as follows: repeat the identification content of the steady-state torque identification module of the valve drive system, but after the motor is connected to the metering valve, the steady-state torque changes, and the calculated steady-state torque is recorded as T2; The method for calculating the steady-state load torque of the metering device is as follows: the steady-state load torque of the metering device in a single test is denoted as T = T2 - T1. The test is repeated ten times, and the average of the results of the ten tests is taken. This average value is the steady-state load torque of the metering device.

10. A method for testing the steady-state load torque of a rotary fuel metering device, characterized in that, The method is applied to the steady-state load torque testing device for the rotary fuel metering device as described in claims 1-9, and the method includes: Step 1: Determine the control plan parameters, including the initial position, final position, acceleration phase, constant speed phase, deceleration phase, acceleration time, constant speed time, and deceleration time of the motor; Step 2: The arithmetic control unit executes the control plan according to the control plan parameters; first, it controls the motor to run to the initial position; after the motor reaches the initial position, it calculates the acceleration according to the acceleration segment and acceleration time, generates a series of speed commands based on the acceleration, and sends the speed commands to the motor speed control loop; when the motor reaches the speed at the end of the acceleration segment, it sends a constant speed command and monitors the motor rotor position in real time. Step 3: Determine if the motor is in a uniform speed state, including: let the current motor speed be n(k), the next motor speed be n(k+1), and the next-next motor speed be n(k+2); define acceleration a(k) = (n(k+1) - n(k)) / ΔT, a(k+1) = (n(k+2) - n(k+1)) / ΔT; if |a(k+1) - a(k)| < ε, then the motor is considered to be in a uniform speed state, record the quadrature-axis current iq1 corresponding to this state, and proceed to step 4; otherwise, the motor is in a non-uniform speed state, where ΔT is the speed sampling period; Step 4: Calculate the no-load torque T1 of the motor according to the algorithm T1=1.5*KT* iq1, where KT is the motor torque coefficient; Step 5: Online operation test of motor-driven metering valve, specifically including: connecting the motor and metering valve through a coupling, so that the motor drives the metering valve to rotate, and the metering device works in actual operation state; when the motor is adjusted to different positions, the fuel flow rate changes with the valve position, then the online operation test of motor-driven metering valve is completed, and proceed to step 6; Step 6: Steady-state torque test of motor and metering valve, specifically including: repeating steps 1 to 4, measuring the motor cross-axis current iq2 when the motor and metering valve move at a constant speed; calculating the current steady-state electromagnetic torque T2 according to the algorithm T2=1.5*KT* iq2, where KT is the motor torque coefficient; Step 7: Calculate the steady-state load torque of the metering device, which includes: recording the steady-state load torque of the metering device in a single test as T = T2 - T1; repeating steps 1 to 6 ten times, recording the test result T for each test, and averaging the results of the ten tests. This average value is the steady-state load torque of the metering device.

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