Generator set grid-connected test system and control method
By designing a generator set grid connection test system, the problem of existing technologies being unable to conduct long-term, multi-condition, large-scale, and high-frequency grid connection tests has been solved, and a comprehensive system verification of the generator set controller has been achieved, which has both theoretical and practical significance.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-25
- Publication Date
- 2026-04-10
AI Technical Summary
Existing generator set controller and engine testing technologies cannot conduct long-term, multi-condition, large-scale, and high-frequency grid connection test research, nor can they conduct high-frequency test research and development of generator set controllers from multiple aspects such as automatic control logic.
A generator set grid-connected test system was designed, including an engine signal simulation unit, an analog-to-RS485 unit, a simulation ECU controller, a diesel generator set controller, a relay protection device, an industrial control integrated computer, an input unit, and a sensor unit. The system realizes signal transmission and processing through different buses and networks, simulates the function of an actual generator set, and provides control methods for single-unit isolated grid operation and single-unit grid-connected operation modes.
It has achieved comprehensive system verification of generator set controllers, without time and space limitations, and can be tested under multiple operating conditions and high-frequency application scenarios, filling the gap in the domestic generator set grid connection technology testing capabilities.
Smart Images
Figure CN121831508A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of generator set control technology, specifically relating to a generator set grid connection test system and method. Background Technology
[0002] With the deepening of international trade disputes, global climate change, and the development of multi-form grid technologies, there is an urgent need to strengthen the reliability and security of power grid supply for specialized power equipment. Emergency power vehicles, as mobile power supply backup equipment, play a crucial role in uninterrupted power supply operations and ensuring power supply for residential use. In recent years, the increasing frequency of extreme weather events globally has led to a surge in demand for emergency power vehicles, making research on grid connection technology for these vehicles of significant practical importance. As a vital component of emergency power vehicles, the generator controller and engine play a core role in grid connection technology. However, existing controller and engine testing technologies lack the capability for long-term, multi-condition, large-scale, and high-frequency grid connection testing, and also cannot conduct high-frequency testing and development of generator controllers from multiple aspects, including automatic control logic. Summary of the Invention
[0003] (a) Purpose of the invention The purpose of this invention is to provide a generator set grid connection test system and method. This system can simulate the various functions of an actual generator set and conduct grid connection technology tests. It can carry out comprehensive and systematic verification work for multiple operating conditions and high-frequency application scenarios. Moreover, the verification process is not limited by time and space, and has great theoretical and practical significance.
[0004] (II) Technical Solution To address the aforementioned problems, a first aspect of the present invention provides a generator set grid connection test system, characterized in that it comprises: an engine signal simulation unit, an analog-to-RS485 conversion unit, a simulation ECU controller, a diesel generator set controller, a relay protection device, an industrial control integrated computer, an input unit, an output unit, and a sensor unit, wherein... An engine signal simulation unit, an analog quantity to RS485 unit, a simulation ECU controller, and a diesel generator set controller are connected in sequence. An industrial control integrated computer and a relay protection device are also provided between the simulation ECU controller and the diesel generator set controller. The industrial control integrated computer and the relay protection device are connected in sequence. The other end of the industrial control integrated computer is connected to the simulation ECU controller, and the other end of the relay protection device is connected to the diesel generator set controller. The diesel generator set controller is also connected to a sensor unit, an input unit, and an output unit. The engine signal simulation unit transmits analog signals to an analog-to-RS485 converter, which receives the analog signals and feeds them back to the analog ECU controller. The diesel generator set controller transmits its own generated diesel generator set controller signals to the analog ECU controller. The analog ECU controller receives the feedback signals from the analog-to-RS485 converter and the diesel generator set controller signals, processes them, and transmits them to the industrial control computer. The industrial control computer receives and parses the signals from the analog ECU controller, then forwards the parsed signals to the relay protection device. The relay protection device performs electrical quantity processing on the received signals and feeds them back to the diesel generator set controller. The sensor unit collects relevant operating parameters of the diesel generator set in real time and feeds them back to the diesel generator set controller. The input unit inputs external switching signals to the diesel generator set controller. The diesel generator unit controller is also used to receive signals from the relay protection device, receive monitoring data from the sensor unit and input signals from the input unit, and output control signals to the output unit.
[0005] Preferably, the diesel generator unit controller and the analog ECU controller communicate via a CAN bus.
[0006] Preferably, the analog-to-RS485 unit and the analog ECU controller communicate via an RS485 bus.
[0007] Preferably, the analog ECU controller and the industrial control computer communicate via Ethernet.
[0008] Preferably, the industrial control all-in-one computer and the relay protection device communicate via Ethernet.
[0009] Preferably, both the engine signal simulation unit and the sensor unit include multiple resistive potentiometers.
[0010] In addition, a second aspect of the present invention provides a control method for a generator set grid-connected test system as described above, the control method including a single-unit isolated grid operation mode and a single-unit grid-connected operation mode.
[0011] Preferably, the stand-alone isolated network operation mode includes: Perform initialization operations on the diesel generator set controller, the analog ECU controller, and the industrial control computer respectively; Input the current load power on the industrial control computer; Based on the load power, the relay protection device's API function is called to control the relay protection device to match the corresponding load data; After matching is completed, the diesel generator unit controller is started. Based on the load power, the generator unit controller adjusts the power generation and issues power generation commands. The analog ECU controller forwards the power generation command to the industrial control computer. The industrial control computer parses the power generation command and sends an execution command to the relay protection device after parsing. The relay protection device delivers power according to the execution command to realize the power supply to the target load. The program has ended.
[0012] Preferably, the stand-alone grid-connected operation mode includes: Perform initialization operations on the diesel generator set controller, the analog ECU controller, and the industrial control computer respectively; Input simulated mains power data into the industrial control all-in-one computer, and perform parameter matching on the simulated mains power data by calling the API function of the relay protection device; After matching is completed, the generator unit is started via the diesel generator controller and a corresponding CAN message is generated; The analog ECU controller receives and processes the CAN message, and then transmits the processed CAN message to the industrial control all-in-one computer via Ethernet. The industrial control integrated computer converts the format of the processed CAN message, and then uses the relay protection device's API function to realize the relay protection device's power output. Start the grid-connected synchronous operation of the diesel generator unit controller, and monitor in real time whether the voltage difference, frequency difference and phase difference meet the preset requirements. Determine whether to trigger the circuit breaker to close based on the detection results. The program has ended.
[0013] Preferably, the real-time detection of whether the voltage difference, frequency difference, and phase difference meet preset requirements, and the determination of whether to trigger the circuit breaker to close based on the detection results, includes: If the voltage difference ΔV < 5V, the frequency difference Δf < 0.1Hz, and the phase difference If all three conditions are met, the circuit breaker will be closed and the grid-connected operation mode will be switched on. If the voltage difference ΔV < 5V, the frequency difference Δf < 0.1Hz, and the phase difference If at least one condition is not met, the circuit breaker will not be closed, and the grid connection synchronization operation will continue until all conditions are met.
[0014] (III) Beneficial Effects The above-mentioned technical solution of the present invention has the following beneficial technical effects: The present invention provides a generator set grid connection test system and method. This system can simulate various functions of an actual generator set and conduct grid connection technology tests, which has great theoretical and practical significance. The specific connection of each unit is as follows: the engine signal simulation unit, the analog-to-RS485 unit, the analog ECU controller, and the diesel generator set controller are connected in sequence. The engine signal simulation unit can transmit relevant analog signals to the analog-to-RS485 unit, and then feed back the analog data to the analog ECU controller based on the RS485 bus. An industrial control integrated computer and a relay protection device are also provided between the analog ECU controller and the diesel generator set controller. The industrial control integrated computer and the relay protection device are connected in sequence. The other end of the industrial control integrated computer is connected to the analog ECU controller, and the other end of the relay protection device is connected to the diesel generator set controller. The analog ECU controller is used to send voltage / current power-on data to the industrial control integrated computer. The program in the industrial control integrated computer parses the data and then uses the relay protection device's API function to realize the control output of the voltage / current of the relay protection device. The diesel generator set controller is also connected to the sensor unit, the input unit, and the output unit respectively. This application can simulate various functions of actual generator sets and conduct grid connection technology tests, possessing significant theoretical and practical value. This invention allows for laboratory research on generator set grid connection technology and further verification of the generator set controller's functions, without time or space limitations. For multi-condition and high-frequency application scenarios, test personnel can conduct comprehensive verification work, filling a gap in domestic generator set grid connection technology testing capabilities. Attached Figure Description
[0015] Figure 1 This is a schematic diagram of the generator set grid connection test system of the present invention; Figure 2 This is a flowchart of a specific embodiment of the single-machine islanded load-carrying process of the present invention; Figure 3 This is a flowchart of a single-machine grid connection according to a specific embodiment of the present invention; Figure 4 This is a schematic diagram illustrating the grid-connected synchronization implementation principle of a specific embodiment of the present invention. Detailed Implementation
[0016] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and the accompanying drawings. It should be understood that these descriptions are merely exemplary and not intended to limit the scope of the invention. Furthermore, descriptions of well-known structures and techniques are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.
[0017] like Figure 1As shown, the first aspect of the present invention provides a generator set grid connection test system, comprising: an engine signal simulation unit, an analog-to-RS485 conversion unit, an analog ECU controller, a diesel generator set controller, a relay protection device, an industrial control integrated computer, an input unit, an output unit, and a sensor unit. The engine signal simulation unit, the analog-to-RS485 conversion unit, the analog ECU controller, and the diesel generator set controller are sequentially connected. The analog-to-RS485 conversion unit and the analog ECU controller communicate via an RS485 bus, and the diesel generator set controller and the analog ECU controller communicate via a CAN bus. The engine signal simulation unit transmits analog signals to an analog-to-RS485 converter, which receives the analog signals and feeds them back to the analog ECU controller. The diesel generator set controller transmits its own generated diesel generator set controller signals to the analog ECU controller. The analog ECU controller receives the feedback signals from the analog-to-RS485 converter and the diesel generator set controller signals, processes them, and transmits them to the industrial control computer. The industrial control computer receives and analyzes the signals from the analog ECU controller, then forwards the analyzed signals to the relay protection device. The relay protection device performs electrical quantity processing on the received signals and feeds them back to the diesel generator set controller. The sensor unit collects relevant operating parameters of the diesel generator set in real time and feeds them back to the diesel generator set controller. The input unit inputs external switching signals to the diesel generator set controller. The diesel generator set controller also receives signals from the relay protection device, receives monitoring data from the sensor unit, and input signals from the input unit, and outputs control signals to the output unit. The engine signal simulation unit includes multiple resistive potentiometers. The engine signal simulation unit consists of 22 resistive potentiometers, which transmit relevant analog signals to an analog-to-RS485 converter module, and then feed the analog data back to the analog ECU controller via the RS485 bus. The 22 resistive potentiometer signals represent: engine speed, engine oil pressure, refrigerant pressure, refrigerant level, fuel pressure, ECU battery voltage, charger voltage, refrigerant temperature, fuel temperature, engine oil temperature, intake port pressure, intake port temperature, turbine pressure, exhaust port temperature, fuel consumption, throttle position, cumulative fuel consumption, current speed load percentage, combustion gas pressure, exhaust oxygen content, turbine temperature, and fuel valve position. An integrated industrial control unit and a relay protection device are also installed between the analog ECU controller and the diesel generator set controller. These are connected sequentially, with one end of the integrated industrial control unit connected to the analog ECU controller and the other end of the relay protection device connected to the diesel generator set controller. The analog ECU controller and the integrated industrial control unit communicate via Ethernet.The analog ECU controller sends voltage / current power-up data to the industrial control computer via Ethernet. The program within the industrial control computer parses the data and then uses the relay protection device's API functions to control the voltage / current output of the relay protection device. The diesel generator unit controller is also connected to a sensor unit, an input unit, and an output unit. The sensor unit includes four resistive potentiometers: water temperature, oil pressure, oil level, and standby. The input unit includes 16 digital input signals, including GCB closed (generator outlet circuit breaker closed position), MCB (molded case circuit breaker closed position), LIS closed (local disconnect switch closed position), and grid-connected mode input. The output unit includes 16 digital output signals, including starter motor, starter oil pump, GCB closed, GCB open, MCB closed, and MCB open.
[0018] In addition, a second aspect of the present invention provides a control method for a generator set grid-connected test system as described above, the control method including a single-unit isolated grid operation mode and a single-unit grid-connected operation mode.
[0019] In the method described, such as Figure 2 As shown, the stand-alone isolated network (stand-alone island) operation mode includes: (1) Perform initialization operations on the diesel generator set controller, the analog ECU controller, and the industrial control unit respectively. The system data initialization in this step mainly includes the initialization of the diesel generator set controller data, the initialization of the analog ECU controller data, and the initialization of the industrial control unit data; (2) Input the current load power on the industrial control computer; (3) Based on the load power, call the relay protection device API function to control the relay protection device to match the corresponding load data. Specifically, through the relay protection device API function, power on the voltage / current of the relay protection device at the load end.
[0020] (4) After the matching is completed, the diesel generator set controller is started. Based on the load power, the generator set controller adjusts the power generation and issues a power generation command. Specifically: the generator set controller starts running and the diesel generator set controller adaptively outputs power based on the load power.
[0021] (5) The power generation command is forwarded from the simulated ECU controller to the industrial control computer. The industrial control computer parses the power generation command and, after parsing, issues an execution command to the relay protection device. The relay protection device delivers power according to the execution command to achieve power supply to the target load. Specifically, the relay protection device simulates power generation and supply through the simulated ECU controller, and the single-unit islanded operation simulates load operation.
[0022] (6) The program ends.
[0023] In addition, such as Figure 3 As shown, the stand-alone grid-connected operation mode in the method includes: (1) Perform initialization operations on the diesel generator set controller, the analog ECU controller, and the industrial control unit respectively. This step involves initializing system data, mainly including initializing the diesel generator set controller data, the analog ECU controller data, and the industrial control unit data.
[0024] (2) Input the analog mains power data into the industrial control all-in-one computer, and perform parameter matching on the analog mains power data by calling the relay protection device API function. Specifically, the industrial control all-in-one computer inputs analog mains power voltage / current and other related data, and processes the above data based on the relay protection device API function.
[0025] (3) After the matching is completed, the generator set controller starts up and generates the corresponding CAN message. Specifically, the generator set controller generates a CAN message for the generator set, which mainly contains information such as the generator set frequency, so that the ECU controller can easily parse it.
[0026] (4) The CAN message is received and processed by the analog ECU controller, and then the processed CAN message is transmitted to the industrial control computer via Ethernet. Specifically, the analog ECU controller CAN message processing is performed to process the received CAN message and then convert it to transmit the data to the industrial control computer via Ethernet.
[0027] (5) The CAN message after processing is converted by the industrial control computer, and the power output of the relay protection device is realized by the API function of the relay protection device. Specifically, the industrial control computer has an application program that can receive the message from the simulated ECU controller and convert the message data. The relay protection device is powered on by the API function of the relay protection device. Based on the API function, the relay protection device is powered on by the simulated mains power / generator power output.
[0028] (6) Start the grid-connection synchronization operation (synchronization check operation) of the diesel generator unit controller, and detect in real time whether the voltage difference, frequency difference and phase difference meet the preset requirements. Determine whether to trigger the circuit breaker to close based on the detection results. The real-time detection of whether the voltage difference, frequency difference and phase difference meet the preset requirements and determine whether to trigger the circuit breaker to close based on the detection results includes: 1. If the voltage difference ΔV < 5V, the frequency difference Δf < 0.1Hz and the phase difference If all three conditions are met, the circuit breaker will be closed and the grid-connected operation mode will be switched on. 2. If the voltage difference ΔV < 5V, the frequency difference Δf < 0.1Hz, and the phase difference... If at least one condition is not met, the circuit breaker will not be closed, and the grid connection synchronization operation will continue until all conditions are met.
[0029] (7) The program ends.
[0030] The schematic diagram for achieving grid-connected synchronization in the stand-alone grid-connected operation mode is as follows: Figure 4 As shown: 1) The mains voltage frequency and the generator voltage frequency are set to 50Hz and 49.97Hz, respectively; 2) Calculation of the phase difference between the generator voltage and the mains voltage; 3) When the frequency difference Δf < 0.1Hz, the phase difference If all conditions are met, proceed to the next step; otherwise, continue with the phase difference calculation. 4) When the voltage difference between the generator and the mains meets the condition, the circuit breaker closing signal is output; 5) Simultaneously complete the signal to the input port of the relay protection device, and control the mains power / generator frequency of the relay protection device to be 50Hz; 6) Program ends.
[0031] It should be understood that the specific embodiments described above are merely illustrative or explanatory of the principles of the invention and do not constitute a limitation thereof. Therefore, any modifications, equivalent substitutions, improvements, etc., made without departing from the spirit and scope of the invention should be included within the protection scope of the invention. Furthermore, the appended claims are intended to cover all variations and modifications falling within the scope and boundaries of the appended claims, or equivalent forms of such scope and boundaries. The invention has been described above with reference to embodiments thereof. However, these embodiments are merely illustrative and not intended to limit the scope of the invention. The scope of the invention is defined by the appended claims and their equivalents. Various substitutions and modifications can be made by those skilled in the art without departing from the scope of the invention, and all such substitutions and modifications should fall within the scope of the invention. Those skilled in the art should understand that embodiments of the invention can be provided as methods, systems, or computer program products. Therefore, the invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Moreover, the invention can take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code. These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1The functions specified in one or more boxes. Those skilled in the art will understand that all or part of the steps in the methods of the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, it includes the flows of the embodiments of the methods described above. The storage medium can be a magnetic disk, optical disk, read-only memory (ROM), or random access memory (RAM), etc. The steps in the methods of the embodiments of the present invention can be adjusted, merged, and deleted according to actual needs. The modules in the system of the embodiments of the present invention can be merged, divided, and deleted according to actual needs.
Claims
1. A generator set grid connection test system, characterized in that, include: The system includes an engine signal simulation unit, an analog-to-RS485 converter, an analog ECU controller, a diesel generator set controller, a relay protection device, an industrial control integrated computer, an input unit, an output unit, and a sensor unit. An engine signal simulation unit, an analog quantity to RS485 unit, a simulation ECU controller, and a diesel generator set controller are connected in sequence. An industrial control integrated computer and a relay protection device are also provided between the simulation ECU controller and the diesel generator set controller. The industrial control integrated computer and the relay protection device are connected in sequence. The other end of the industrial control integrated computer is connected to the simulation ECU controller, and the other end of the relay protection device is connected to the diesel generator set controller. The diesel generator set controller is also connected to a sensor unit, an input unit, and an output unit. The engine signal simulation unit is used to transmit analog signals to the analog-to-RS485 unit, and the analog-to-RS485 unit is used to receive the analog signals and feed them back to the analog ECU controller. The diesel generator unit controller is used to transmit the diesel generator unit controller signal it generates to the analog ECU controller; The analog ECU controller is used to receive feedback signals from the analog quantity to RS485 unit and signals from the diesel generator set controller, process them, and then transmit them to the industrial control computer. The industrial control integrated computer is used to receive and parse the signals from the analog ECU controller, and then forward the parsed signals to the relay protection device; The relay protection device is used to process the received signal into electrical quantities and then feed it back to the diesel generator unit controller; the sensor unit is used to collect relevant operating parameters of the diesel generator unit in real time and feed them back to the diesel generator unit controller; the input unit is used to input external switching signals to the diesel generator unit controller. The diesel generator unit controller is also used to receive signals from the relay protection device, receive monitoring data from the sensor unit and input signals from the input unit, and output control signals to the output unit.
2. The generator set grid connection test system according to claim 1, characterized in that, The diesel generator unit controller and the analog ECU controller communicate via a CAN bus.
3. The generator set grid connection test system according to claim 1, characterized in that, The analog-to-RS485 unit and the analog ECU controller communicate via an RS485 bus.
4. The generator set grid connection test system according to claim 1, characterized in that, The analog ECU controller and the industrial control computer communicate via Ethernet.
5. The generator set grid connection test system according to claim 1, characterized in that, The industrial control all-in-one computer and the relay protection device communicate via Ethernet.
6. The generator set grid connection test system according to claim 1, characterized in that, Both the engine signal simulation unit and the sensor unit include multiple resistive potentiometers.
7. A control method for a generator set grid-connected test system based on any one of claims 1-6, characterized in that, The control method includes a stand-alone isolated network operation mode and a stand-alone grid-connected operation mode.
8. The control method based on the generator set grid connection test system according to claim 7, characterized in that, The isolated network operation mode includes: Perform initialization operations on the diesel generator set controller, the analog ECU controller, and the industrial control computer respectively; Input the current load power on the industrial control computer; Based on the load power, the relay protection device's API function is called to control the relay protection device to match the corresponding load data; After matching is completed, the diesel generator unit controller is started. Based on the load power, the generator unit controller adjusts the power generation and issues power generation commands. The analog ECU controller forwards the power generation command to the industrial control computer. The industrial control computer parses the power generation command and sends an execution command to the relay protection device after parsing. The relay protection device delivers power according to the execution command to realize the power supply to the target load. The program has ended.
9. The control method based on the generator set grid connection test system according to claim 7, characterized in that, The stand-alone grid-connected operation mode includes: Perform initialization operations on the diesel generator set controller, the analog ECU controller, and the industrial control computer respectively; Input simulated mains power data into the industrial control all-in-one computer, and perform parameter matching on the simulated mains power data by calling the API function of the relay protection device; After matching is completed, the generator unit is started via the diesel generator controller and a corresponding CAN message is generated; The analog ECU controller receives and processes the CAN message, and then transmits the processed CAN message to the industrial control all-in-one computer via Ethernet. The industrial control integrated computer converts the format of the processed CAN message, and then uses the relay protection device's API function to realize the relay protection device's power output. Start the grid-connected synchronous operation of the diesel generator unit controller, and monitor in real time whether the voltage difference, frequency difference and phase difference meet the preset requirements. Determine whether to trigger the circuit breaker to close based on the detection results. The program has ended.
10. The control method based on the generator set grid connection test system according to claim 9, characterized in that, The real-time detection of voltage difference, frequency difference, and phase difference to determine whether to trigger circuit breaker closing based on the detection results includes: If the voltage difference ΔV < 5V, the frequency difference Δf < 0.1Hz, and the phase difference If all three conditions are met, the circuit breaker will be closed and the grid-connected operation mode will be switched on. If the voltage difference ΔV < 5V, the frequency difference Δf < 0.1Hz, and the phase difference If at least one condition is not met, the circuit breaker will not be closed, and the grid synchronization operation will continue until all conditions are met.