Control system and method for scramjet direct connection engine test flow regulating valve

Abstract

The invention relates to the field of scramjet direct connection tests, in particular to a control system and method for a scramjet direct connection engine test flow regulating valve, and aims at solving the problem that when an existing electric control valve and an existing pneumatic control valve are applied to a scramjet direct connection test, the requirements for quick response, high-precision control, high reliability and low cost cannot be met at the same time. The system comprises an upper computer, a lower computer, a motor driver, a servo motor and a motion electric cylinder. The upper computer is used for generating and sending a control data packet; the lower computer receives and analyzes the control data packet to generate a corresponding servo control instruction, and the motor driver drives the servo motor; the speed reducer drives the moving electric cylinder to move, and then the opening degree of the valve is adjusted. Meanwhile, the method comprises the steps of system initialization, zero positioning, instruction issuing and analysis, control instruction production, motion execution, state feedback and monitoring and fault diagnosis and alarm. According to the invention, rapid, high-precision and high-reliability adjustment of the test liquid flow of the scramjet direct-connection engine is realized.

Description

Technical Field

[0001] This invention relates to the field of scramjet direct-drive testing, and more specifically to a control system and method for a flow control valve used in scramjet direct-drive engine testing. Background Technology

[0002] Scramjet direct-drive engine testing is a key ground testing method in the propulsion field. It requires the incoming flow simulation system (such as a three-component liquid oxygen / alcohol / air heating device) to quickly and accurately complete multiple operating condition changes and stage transitions in a single hot run. This places extremely stringent requirements on the flow control system supplying the cryogenic liquid (such as liquid oxygen): the system must have continuous adjustment capability over a wide flow ratio range, a rapid response speed in the millisecond to second range, extremely high adjustment accuracy and repeatability, and reliability and stability in the face of cryogenic media.

[0003] Currently, real-time dynamic regulation of liquid flow in industrial applications and traditional testing commonly employs a method of installing regulating valves in pipelines combined with electric or pneumatic actuators. Electric regulating valves, typically driven by servo motors or stepper motors, offer the advantage of high positioning accuracy during continuous regulation; however, their system configuration is complex, and servo motors face stringent explosion-proof requirements in flammable and explosive testing environments, leading to high costs. More importantly, the full-stroke action time of conventional electric valves is usually quite long, at least 10 seconds, failing to meet the second-level or even sub-second-level rapid switching requirements of testing. Pneumatic regulating valves, driven by air pressure, offer advantages such as system simplicity, lower cost, and relatively fast action speed; however, their accuracy during continuous regulation is lower, and they are significantly affected by factors such as fluctuations in air source pressure and changes in valve friction, resulting in poor stability, repeatability, and long-term reliability, making it difficult to achieve high-precision closed-loop flow control.

[0004] Most existing industrial control systems are designed to operate under rated conditions or at a limited number of fixed operating points, where valves do not require frequent and rapid dynamic adjustments. Therefore, the drawbacks of the aforementioned electric or pneumatic solutions are not significant. However, in scramjet direct-drive tests, control valves are required to achieve continuous, stable, and rapid changes in multi-stage, high-ratio operating conditions within a short period (e.g., during a single test run). Existing general-purpose pneumatic control methods cannot meet these requirements due to insufficient accuracy and repeatability; while conventional electric valves suffer from bottlenecks due to slow response speeds. There is a lack of dedicated cryogenic liquid flow control valves on the market that simultaneously offer rapid response, high-precision control, high reliability, and a reasonable cost. Summary of the Invention

[0005] The purpose of this invention is to solve the technical problem that existing electric and pneumatic regulating valves cannot simultaneously meet the requirements of fast response, high precision control, high reliability and low cost when applied to scramjet direct-drive tests, and to provide a control system and method for a flow control valve for scramjet direct-drive engine tests.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A control system for a flow control valve used in a scramjet direct-drive engine test is characterized by including a host computer, a slave computer, a motor driver, a servo motor, and a motion cylinder. The host computer is connected to the slave computer and is used to generate and send control data packets containing a single target opening instruction or timing instruction to the slave computer, and to receive, parse, display and store status data packets from the slave computer. The lower-level machine is equipped with a data acquisition input terminal and a pulse control signal output terminal; the pulse output terminal is electrically connected to the control signal input terminal of the motor driver, and is used to receive and parse the control data packet sent by the upper-level machine, generate corresponding servo control commands, and send the servo control commands to the motor driver; The data output terminal of the motor driver is electrically connected to the control terminal of the servo motor to drive the servo motor to operate; its data input terminal is electrically connected to the encoder feedback terminal of the servo motor to receive encoder data reflecting the operating status of the servo motor; a reducer is connected to the output shaft of the servo motor; the output shaft of the reducer is connected to the input terminal of the motion cylinder; the output terminal of the motion cylinder is used to connect to the valve stem of the scramjet direct-drive engine test flow control valve, so as to adjust the valve opening of the scramjet direct-drive engine test flow control valve by the displacement of the output terminal of the motion cylinder; The input terminal of the lower-level machine is electrically connected to the data output terminal of the motor driver and the valve opening sensor of the scramjet direct-drive engine test flow control valve, respectively, so as to collect data on the servo motor operating status from the motor driver and the valve opening feedback data from the valve opening sensor in real time.

[0007] Furthermore, the host computer includes a unit testing module, a data storage module, a data processing module, a communication module, a timing module, a data display module, a timing editing module, and a timing verification module; The communication module is electrically connected to the lower-level machine via an Ethernet physical interface. It is used to encapsulate and send control data packets to the lower-level machine, and to receive and decode status data packets from the lower-level machine. The input terminal of the data processing module is electrically connected to the output terminal of the communication module, and is used to parse, verify, convert units and calculate engineering values ​​of the decoded status data packets to obtain processed real-time data and system events; the output terminal of the data processing module is electrically connected to the first input terminal of the data storage module and the first input terminal of the data display module, respectively, and the data storage module is used to store the real-time data and system events in a predefined format; The second and third input terminals of the data display module are electrically connected to the output terminal of the data storage module and the first output terminal of the timing module, respectively. They are used to call the real-time data of the data processing module and the historical data of the data storage module, and display the flow rate, opening degree, torque, pressure and system status parameters in the form of curves, values ​​and dashboards, and refresh the interface periodically. The output of the unit test module is electrically connected to the first input of the communication module, and is used to send a control data packet containing a single target opening instruction to the lower-level computer through the communication module. The output terminal of the timing editing module is electrically connected to the second input terminal of the data storage module and the input terminal of the timing verification module, respectively, and is used to send the test timing instructions created by the timing editing module to the timing verification module and store them in the data storage module; The output of the timing verification module is electrically connected to the input of the timing module, and is used to send timing instructions that have passed the verification by the timing verification module to the timing module; the second output of the timing module is electrically connected to the second input of the communication module, and is used to periodically send control data packets containing timing instructions to the lower-level machine.

[0008] Furthermore, the lower-level machine includes a data acquisition module, a servo motor drive module, a network communication module, a timer interrupt module, an opening degree calculation and output module, an initialization module, and an alarm output module; The initialization module is used to configure the hardware ports and initial parameters of the data acquisition module, servo motor drive module, network communication module, timer interrupt module, opening degree calculation output module and alarm output module once when the system is powered on. The lower-level machine includes an initialization module, as well as a data acquisition module, a servo motor drive module, a network communication module, a timer interrupt module, an opening degree calculation output module, and an alarm output module that initialize hardware ports and parameters when the initialization module is powered on; the network communication module is connected to the communication module of the upper-level machine through an Ethernet interface to form a communication channel for data uplink and downlink. The input terminals of the data acquisition module are electrically connected to the motor driver and the valve opening sensor of the scramjet direct-drive engine test flow control valve, respectively, for real-time acquisition of the actual position and output torque of the servo motor and the valve opening feedback data of the scramjet direct-drive engine test flow control valve; its output terminals are electrically connected to the first input terminal of the opening calculation output module, the first monitoring terminal of the alarm output module and the first input terminal of the network communication module, respectively, for providing real-time data; The second input terminal of the opening degree calculation output module is electrically connected to the network communication module, and is used to acquire the control parameters in the control data packet and the actual position data of the servo motor collected in real time by the data acquisition module, and convert the control parameters and actual position data into servo control commands required to control the servo motor; the first output terminal and the second output terminal of the opening degree calculation output module are electrically connected to the input terminal of the servo motor drive module and the second input terminal of the network communication module, respectively, and are used to package the status data packet containing the control status to the host computer through the network communication module, and send the servo control commands to the servo motor drive module; The pulse signal output terminal of the servo motor drive module is connected to the control port of the motor driver, and the data output terminal of the motor driver is electrically connected to the control terminal of the servo motor, which is used to drive the servo motor to move according to the servo control command issued by the servo motor drive module. The second monitoring terminal of the alarm output module is electrically connected to the third output terminal of the opening calculation output module, and is used to determine whether there is a fault based on the monitored data; its alarm information output terminal is electrically connected to the third input terminal of the network communication module, and is used to package the alarm information when there is a fault into a status data packet through the network communication module and upload it to the host computer. The output terminal of the timer interrupt module is electrically connected to the control terminals of the data acquisition module, the opening degree calculation output module, and the alarm output module, respectively, and is used to trigger periodic scheduling instructions to schedule the data acquisition module, the opening degree calculation output module, and the alarm output module to execute periodically.

[0009] Furthermore, it also includes external alarm devices; The alarm output module is also provided with a local alarm output terminal, which is electrically connected to the control terminal of the external alarm device.

[0010] Meanwhile, the present invention also provides a control method for a flow control valve used in a scramjet direct-drive engine test, which is characterized by including the following steps: S1. Assemble the control system for the flow control valve used in the scramjet direct-drive engine test; S2. Start the control system for the flow control valve used in the scramjet direct-drive engine test, perform system initialization and zero-position positioning, and set the safety range of each operating parameter; S3, Command Issuance and Parsing According to the test requirements of the scramjet direct-drive engine, the host computer sends a control data packet containing a single target opening command or timing command to the slave computer through a custom communication protocol format; after receiving the control data packet, the slave computer performs verification and parsing to extract the control parameters. S4. Control Command Generation The lower-level computer will convert the control parameters obtained by parsing the control data packet into servo control commands containing the total number of pulses and frequency required to control the servo motor. S5, Motion Execution The lower-level machine sends servo control commands to the motor driver; thus, the motor driver drives the servo motor to move according to the servo control commands, and then drives the electric cylinder through the reducer to push the valve stem of the scramjet direct-drive engine test flow control valve connected to its output end to produce linear displacement, thereby changing the valve opening of the scramjet direct-drive engine test flow control valve. S6. Status Feedback and Monitoring The lower-level computer collects the actual position and output torque of the servo motor and the valve opening feedback signal of the scramjet direct-drive engine test flow control valve in real time, and assembles a status data packet according to a custom communication protocol format. The status data packet is then periodically uploaded to the upper-level computer. The upper-level computer parses, displays, and stores the received status data packet. S7. Fault Diagnosis and Alarm The host computer and / or slave computer compare the actual position, output torque and expected value in real time, and monitor the operation status and communication link of the control system of the scramjet direct-drive engine test flow control valve; when any parameter exceeds the preset safety range or communication is abnormal, the specific fault alarm information is immediately triggered and displayed on the human-machine interface of the host computer, so as to realize the control of the scramjet direct-drive engine test flow control valve.

[0011] Furthermore, step S2 specifically includes: S2.1 Start the control system for the flow control valve used in the scramjet direct-drive engine test and perform system initialization; S2.2, Zero Positioning The servo motor is jogged and fine-tuned. At the same time, test gas is applied to the closed pipeline connected to the valve body of the scramjet direct-drive engine test flow control valve, which is connected to the output end of the motion cylinder, and the pressure change is monitored. When the pressure change tends to stabilize and does not change with the opening and closing of the scramjet direct-drive engine test flow control valve and the slight increase of the intake pressure, the encoder feedback value of the servo motor at this time is recorded and set as the zero position reference of the scramjet direct-drive engine test flow control valve. S2.3 Set the safety range for each operating parameter.

[0012] Furthermore, in step S3, the control parameters include a target opening value or a timing opening value; Step S4 is as follows: The lower-level machine will parse the target opening value or timing opening value obtained from the control data packet, combine it with the preset electromechanical transmission ratio and zero position reference, calculate the target angular displacement of the servo motor, and then convert it into a servo control command containing the total number of high-speed pulses and the target pulse frequency required to control the servo motor.

[0013] Furthermore, step S5 specifically includes: S5.1 The lower-level computer sends a servo control command containing the total number of high-speed pulses and the target pulse frequency to the motor driver. S5.2 The motor driver drives the servo motor to rotate in the specified direction and speed according to the servo control command; S5.3 The torque of the servo motor is amplified by the reducer and then transmitted to the motion cylinder; S5.4 The electric cylinder pushes the valve stem of the scramjet direct-drive test flow control valve connected to its output end to produce linear displacement during acceleration, constant speed and deceleration phases, thereby changing the valve opening of the scramjet direct-drive test flow control valve.

[0014] Furthermore, in steps S3 and S6, the custom communication protocol format includes at least the device number, function code, opening instruction, timing time, timing opening, real-time operating parameters, and alarm flag fields.

[0015] Furthermore, in step S4, the lower-level machine converts the control parameters into the total number of pulses and frequency required to control the servo motor via PTO or PWM.

[0016] Compared with the prior art, the present invention has the following beneficial effects: (1) The present invention provides a control system for a flow control valve for a scramjet direct-drive engine test. By integrating the upper computer's instruction generation, the lower computer's rapid closed-loop execution, the servo drive's precise motion, and the linear output of the electric cylinder, the core contradiction of the existing electric control valve's slow response and the pneumatic control valve's poor accuracy and repeatability is solved. This achieves rapid, high-precision, and high-reliability adjustment of the cryogenic liquid flow rate for scramjet direct-drive engine testing, providing a hardware foundation for simulating complex test conditions.

[0017] (2) The present invention provides a control system for a flow control valve used in a scramjet direct-drive engine test. By defining a complete modular architecture in the host computer, including timing editing, verification, timing control, data processing, and display, the present invention achieves visualization, programmability, and high automation of the test process. In particular, the introduction of the timing editing and verification modules ensures the safety and reliability of complex test procedures and avoids human error; the collaboration of the data processing and display modules enables real-time, multi-dimensional monitoring and data traceability of the test status, greatly improving test efficiency and data analysis capabilities.

[0018] (3) The present invention provides a control system for a flow control valve used in a scramjet direct-drive engine test. Through the coordinated operation of modules such as data acquisition, opening degree calculation, servo drive, and fault diagnosis under timed interrupt scheduling, a real-time closed-loop control core with millisecond-level response is formed. The initialization module ensures the reliability of system startup, and the alarm output module enables both local and remote fault responses. This architecture enables the system to not only have high control precision but also possess strong self-diagnosis and fault tolerance capabilities, meeting the extreme stability requirements of the test system.

[0019] (4) A control method for a flow control valve used in a scramjet direct-drive engine test, covering the entire test process from system assembly, initialization, command parsing, motion control to status monitoring and fault diagnosis. Its core lies in seamlessly connecting the intelligent decision-making of the host computer with the rapid execution of the slave computer, and ensuring efficient and reliable transmission of commands and data through a custom communication protocol. This method realizes the streamlining, standardization, and automation of test operations, significantly reducing operational difficulty and the risk of human error, and ensuring the consistency and repeatability of each test.

[0020] (5) A control method for a flow control valve used in a scramjet direct-drive engine test uses the fluid cutoff state as the basis for judging the mechanical zero position. This method has a clear physical meaning, eliminates the influence of mechanical clearance and transmission errors, and achieves high-precision, high-repeatability calibration of the valve's mechanical zero position. This is a prerequisite for subsequent high-precision flow control, fundamentally improving the reference accuracy of the entire control system. Simultaneously, by combining a preset electromechanical transmission ratio with a precise zero-position reference, the spatial positioning problem of the valve opening is transformed into the angular displacement and pulse control problem of the servo motor, achieving precise and efficient mapping from process parameters to underlying drive commands. This is a key calculation step for achieving continuous and smooth transitions between complex multi-level operating conditions, ensuring the linearity and accuracy of the control.

[0021] (6) A control method for a flow control valve for a scramjet direct-drive engine test. By controlling the servo motor, the mechanical shock and flow overshoot during valve start-up and shutdown are effectively avoided, making the valve opening change process not only fast, but also smooth and stable. This is crucial for protecting the precision valve mechanism and maintaining the stability of flow and pressure during the test.

[0022] (7) A control method for a flow control valve in a scramjet direct-drive engine test system employs a custom protocol instead of a general industrial protocol, resulting in extremely high communication efficiency and low redundancy. This method is particularly suitable for fast control scenarios requiring high-frequency, small data packet exchange, ensuring real-time system response and reducing communication load and latency. Simultaneously, the use of PTO (Pulse Train Output) or PWM (Pulse Width Modulation) to drive the servo motor enables the lower-level machine to generate stable and precise motor control signals at extremely low cost and processing overhead. This is a core technology choice for achieving a high-performance, high-precision actuator. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of a control system embodiment for a scramjet direct-drive engine test flow control valve according to the present invention (external alarm device not shown). Figure 2 This is a schematic diagram of the host computer structure in an embodiment of a control system for a scramjet direct-drive engine test flow control valve; Figure 3 This is a schematic diagram of the lower-level machine in an embodiment of a control system for a scramjet direct-drive engine test flow control valve; Figure 4 This is a schematic diagram illustrating the lower-level computer receiving and sending codes via Ethernet in an embodiment of a control system for a scramjet direct-drive engine test flow control valve according to the present invention. Figure 5 This is a schematic diagram of the period and pulse width of the PTO mode in step S3 of an embodiment of the control method for a test flow control valve of a scramjet direct-drive engine according to the present invention. Figure 6 This is a schematic diagram of the period and pulse width of the PWM mode in step S3 of an embodiment of the control method for a test flow control valve of a scramjet direct-drive engine according to the present invention; Figure 7 The code diagram for step S2 of the embodiment of the control method for a flow control valve in a scramjet direct-drive engine test uses a timed interrupt to adjust the flow opening of the flow control valve. Figure 8 This is a schematic diagram of the communication principle between the host computer and the slave computer in step S2 of an embodiment of a control method for a test flow control valve of a scramjet direct-drive engine.

[0024] The attached figures are labeled as follows: 1-Host computer, 11-Unit test module, 12-Data storage module, 13-Data processing module, 14-Communication module, 15-Timing module, 16-Data display module, 17-Timing editing module, 18-Timing verification module, 2-Lower computer, 21-Data acquisition module, 22-Servo motor drive module, 23-Network communication module, 24-Timing interrupt module, 25-Opening degree calculation and output module, 26-Initialization module, 27-Alarm output module, 3-Motor driver, 4-Servo motor, 5-Reducer, 6-Motion cylinder. Detailed Implementation

[0025] To better understand the purpose, structure, and function of this invention, the following detailed description, in conjunction with the accompanying drawings, provides an overview of a control system and method for a scramjet direct-drive engine test flow control valve.

[0026] This invention provides a control system for a flow control valve used in a scramjet direct-drive engine test, such as... Figure 1 As shown, it includes a host computer 1, a slave computer 2, a motor driver 3, a servo motor 4, a reducer 5, a motion cylinder 6, and an external alarm device.

[0027] The host computer 1 communicates with the slave computer 2, generating and sending control data packets containing single-target opening instructions or timing instructions to the slave computer 2, and receiving, parsing, displaying, and storing status data packets from the slave computer 2. The slave computer 2 is equipped with a data acquisition input terminal and a pulse control signal output terminal; the pulse control signal output terminal is electrically connected to the control signal input terminal of the motor driver 3, used to receive and parse the control data packets sent by the host computer 1, generate corresponding servo control instructions, and send the servo control instructions to the motor driver 3.

[0028] The data output terminal of the motor driver 3 is electrically connected to the control terminal of the servo motor 4 to drive the servo motor 4; its data input terminal is electrically connected to the encoder feedback terminal of the servo motor 4 to receive encoder data reflecting the operating status of the servo motor 4; the output shaft of the servo motor 4 is connected to the input terminal of the reducer 5; the output shaft of the reducer 5 is connected to the input terminal of the motion cylinder 6; the output terminal of the motion cylinder 6 is used to connect to the valve stem of the scramjet direct-drive engine test flow control valve, thereby adjusting the valve opening of the scramjet direct-drive engine test flow control valve by the displacement of the output terminal of the motion cylinder 6. The input terminal of the lower-level machine 2 is electrically connected to the data output terminal of the motor driver 3 and the valve opening sensor of the scramjet direct-drive engine test flow control valve, respectively, to collect data on the operating status of the servo motor 4 from the motor driver 3 and the valve opening feedback data from the valve opening sensor in real time. The motion cylinder 6 is made of a low-temperature resistant material, and the Cv value of the scramjet direct-drive engine test flow control valve is 5.39.

[0029] like Figure 2 As shown, the host computer 1 uses an industrial control computer, is programmed using LabVIEW 2020, and runs on the Win10 operating system. The host computer 1 includes a unit test module 11, a data storage module 12, a data processing module 13, a communication module 14, a timing module 15, a data display module 16, a timing editing module 17, and a timing verification module 18. The communication module 14 is electrically connected to the slave computer 2 via an Ethernet physical interface, and is used to encapsulate and send control data packets to the slave computer 2, while simultaneously receiving and decoding status data packets from the slave computer 2.

[0030] The input terminal of the data processing module 13 is electrically connected to the output terminal of the communication module 14, and is used to parse, verify, convert units, and calculate engineering values ​​of the decoded status data packets to obtain processed real-time data and system events. The output terminal of the data processing module 13 is electrically connected to the first input terminal of the data storage module 12 and the first input terminal of the data display module 16, respectively. The data storage module 12 is used to store real-time data and system events in a predefined format. The output terminal of the data storage module 12 is connected to the data display module 16 to support historical data query and playback.

[0031] The second and third input terminals of the data display module 16 are electrically connected to the output terminal of the data storage module 12 and the first output terminal of the timing module 15, respectively. These terminals are used to call real-time data from the data processing module 13 and historical data from the data storage module 12, displaying flow rate, opening degree, torque, pressure, and system status parameters in the form of curves, numerical values, and dashboards, and periodically refreshing the interface. The output terminal of the unit test module 11 is electrically connected to the first input terminal of the communication module 14, used to send control data packets containing a single target opening degree command to the lower-level computer 2 via the communication module 14. The output terminal of the timing editing module 17 is electrically connected to the second input terminal of the data storage module 12 and the input terminal of the timing verification module 18, respectively. This allows the timing instructions created by the timing editing module 17 to be sent to the timing verification module 18 and stored in the data storage module 12. The timing editing module 17's human-machine interface is used to receive user input to create or modify the test timing program.

[0032] The output of the timing verification module 18 is electrically connected to the input of the timing module 15, and is used to send the timing instructions that have passed the verification by the timing verification module 18 to the timing module 15; the second output of the timing module 15 is electrically connected to the second input of the communication module 14, and is used to periodically send control data packets containing timing instructions to the lower computer 2.

[0033] like Figure 3 As shown, the lower-level machine 2 can be programmed using Siemens STEP 7-200 and LAD, and includes a data acquisition module 21, a servo motor drive module 22, a network communication module 23, a timer interrupt module 24, an opening degree calculation output module 25, an initialization module 26, and an alarm output module 27. Among them, the initialization module 26 is used to configure the hardware ports and initial parameters of the data acquisition module 21, servo motor drive module 22, network communication module 23, timer interrupt module 24, opening degree calculation output module 25, and alarm output module 27 once when the system is powered on.

[0034] The network communication module 23 is connected to the communication module 14 of the host computer 1 via an Ethernet interface, forming a communication channel for data uplink and downlink; the schematic diagram of the slave computer 2 receiving and sending codes via Ethernet is shown below. Figure 4 As shown. The input terminals of the data acquisition module 21 are electrically connected to the motor driver 3 and the valve opening sensor of the scramjet direct-drive engine test flow control valve, respectively, for real-time acquisition of the actual position, output torque of the servo motor 4 and the valve opening feedback data of the scramjet direct-drive engine test flow control valve; its output terminals are electrically connected to the first input terminal of the opening calculation output module 25, the first monitoring terminal of the alarm output module 27 and the first input terminal of the network communication module 23, respectively, for providing real-time data.

[0035] The second input terminal of the opening calculation output module 25 is electrically connected to the network communication module 23, and is used to acquire the control parameters in the control data packet and the actual position data of the servo motor 4 collected in real time by the data acquisition module 21, and convert the control parameters and actual position data into servo control commands required to control the servo motor 4; the first and second output terminals of the opening calculation output module 25 are electrically connected to the input terminal of the servo motor drive module 22 and the second input terminal of the network communication module 23, respectively, and are used to package the status data packet containing the control status to the host computer 1 through the network communication module 23, and send the servo control commands to the servo motor drive module 22; the pulse signal output terminal of the servo motor drive module 22 is connected to the control port of the motor driver 3, and the data output terminal of the motor driver 3 is electrically connected to the control terminal of the servo motor 4, and is used to drive the servo motor 4 to move according to the servo control commands issued by the servo motor drive module 22.

[0036] The second monitoring terminal of the alarm output module 27 is electrically connected to the third output terminal of the opening calculation output module 25, and is used to determine whether a fault exists based on the monitored data. Its alarm information output terminal is electrically connected to the third input terminal of the network communication module 23, and is used to package the alarm information when a fault exists into a status data packet and upload it to the host computer 1 via the network communication module 23. The output terminal of the timer interrupt module 24 is electrically connected to the control terminals of the data acquisition module 21, the opening calculation output module 25, and the alarm output module 27, respectively, and is used to trigger periodic scheduling commands to schedule the data acquisition module 21, the opening calculation output module 25, and the alarm output module 27 to execute periodically. The alarm output module 27 also has a local alarm output terminal, which is electrically connected to the control terminal of an external alarm device.

[0037] In this embodiment, the lower-level machine 2 can be a Siemens PLC (CPU ST40 DC / DC / DC) transistor output type, which has 16 digital outputs (3 high-speed pulse outputs) and 24 digital inputs. High-speed pulse output refers to generating high-speed pulses at certain output terminals of the programmable controller to drive the load and achieve precise control. When using the high-speed pulse output function, the PLC host should be a transistor output type to meet the frequency requirements of high-speed output. High-speed pulse train output can be controlled by interrupt mode. The lower-level machine 2 has two available high-speed pulse train output interrupt events, namely interrupt events 19 and 20. Interrupt event 19 refers to the completion interruption of PTO0 pulse train output; interrupt event 20 refers to the completion interruption of PTO1 pulse train output. During the servo motor operation control process, the lower-level machine 2 converts the opening displacement value of the electric cylinder 6 into the number of pulses for the servo motor 4 to execute the movement, and the lower-level machine 2 outputs the corresponding number of pulses through high-speed pulse output.

[0038] Based on the above-described control system for a scramjet direct-drive engine test flow control valve, the present invention also provides a control method for a scramjet direct-drive engine test flow control valve, comprising the following steps: S1. Start the control system for the flow control valve used in the scramjet direct-drive engine test, perform system initialization and zero-position positioning, and set the safety range of each operating parameter.

[0039] S1.1 Start the control system for the flow control valve used in the scramjet direct-drive engine test and perform system initialization; S1.2, Zero Positioning The servo motor 4 is jogged and fine-tuned to detect changes in torque, actual displacement, and pressure in the system pipeline. Simultaneously, test gas is applied to the closed pipeline connected to the valve body of the scramjet direct-drive engine test flow control valve, which is connected to the output of the electric cylinder 6, and pressure changes are monitored. When the pressure changes stabilize and do not change with the opening and closing of the scramjet direct-drive engine test flow control valve or the slight increase in intake pressure, the encoder feedback value of the servo motor 4 is recorded and set as the zero-position reference of the scramjet direct-drive engine test flow control valve. S1.3, Set the safety range for each operating parameter.

[0040] S2, Command Issuance and Parsing Based on the testing requirements of the scramjet direct-drive engine, host computer 1 sends a control data packet containing a single target opening command or timing command to slave computer 2 via a custom communication protocol format. After receiving the control data packet, slave computer 2 verifies and parses it to extract the control parameters. These control parameters include the target opening value or the timing opening value. The custom communication protocol formats for host computer 1 and slave computer 2 are shown in Table 1 (Communication Protocol Format for Host Computer Data Transmission) and Table 2 (Communication Protocol Format for Slave Computer Data Transmission). Table 1. Communication Protocol Format for Data Transmission from Host Computer Table 2 Communication Protocol Format for Lower-Level Machine Data Transmission As shown in the table above, the custom communication protocol format between host computer 1 and slave computer 2 includes the device number, function code, opening command, timing time, timing opening, real-time operating parameters, and alarm flag fields. Host computer 1 parses the received data according to the pre-defined protocol, assigns the values ​​to the corresponding variables, and then performs the next step of logic control.

[0041] The timing instructions can be used by the lower-level machine 2 to adjust the flow opening of the flow control valve via a timed interrupt. The timing interval for the timed interrupt control can be set to 10ms. The code for controlling the flow opening of the flow control valve with a 10ms timer is as follows: Figure 7 As shown, the opening adjustment is performed using a timer interrupt period of no more than 10ms. This feature fixes the rhythm of the entire closed-loop control on a high-frequency, deterministic timing sequence, ensuring the strict periodicity of data acquisition, algorithm calculation, and command output. This fundamentally eliminates the response delay and uncertainty caused by traditional polling methods or long-cycle control, providing the timing basis for the system to achieve fast and stable responses (such as meeting second-level operating condition switching), and improving the system's dynamic performance and control quality.

[0042] The host computer 1 and the slave computer 2 communicate via Ethernet. Host computer 1 sends test parameter (unit test commands, test timing) data packets to slave computer 2 via Ethernet. Slave computer 2 parses the data packets using a custom communication protocol, executes the protocol commands, and uploads its operating parameters back to host computer 1 for real-time monitoring. The communication principle diagram between host computer 1 and slave computer 2 is shown below. Figure 8 As shown.

[0043] Whenever the host computer 1 issues a control command, the command is verified to ensure its correctness. After receiving the command, the slave computer 2 parses it and uploads it to the host computer 1, then executes the control command. At the same time, the slave computer 2 communicates with the servo motor 4 via a bus to obtain parameters such as the position, torque, and operating status of the servo motor 4, and sends these parameters to the host computer 1 for real-time monitoring through a network communication protocol.

[0044] S3, Control Command Generation The lower-level machine 2 parses the control parameters (target opening value or timing opening value) obtained from the control data packet, combines them with the preset electromechanical transmission ratio and zero-position reference, calculates the target angular displacement of the servo motor 4, and then converts it into a servo control command containing the total number of high-speed pulses and the target pulse frequency required to control the servo motor 4. Specifically, the lower-level machine 2 converts the control parameters into the total number of pulses and frequency required to control the servo motor 4 through PTO or PWM. PTO can output a series of pulses (50% duty cycle), and the user can control the period and number of pulses, such as... Figure 5 As shown. PWM can output a series of pulses with adjustable duty cycles, and the user can control the pulse period and pulse width, such as... Figure 6 As shown.

[0045] S4, Motion Execution The lower-level machine 2 sends a servo control command to the motor driver 3; thereby, the motor driver 3 drives the servo motor 4 to move according to the servo control command, and then drives the motion cylinder 6 through the reducer 5 to push the valve stem of the scramjet direct-drive engine test flow control valve connected to its output end to produce a linear displacement, thereby changing the valve opening of the scramjet direct-drive engine test flow control valve.

[0046] S4.1 The lower-level machine 2 sends a servo control command containing the total number of high-speed pulses and the target pulse frequency to the motor driver 3; S4.2 The motor driver 3 drives the servo motor 4 to rotate in the specified direction and speed according to the servo control command; S4.3 The torque of the servo motor 4 is amplified by the reducer 5 and then transmitted to the motion cylinder 6; S4.4, the electric cylinder 6 pushes the valve stem of the scramjet direct-drive test flow control valve connected to its output end to produce linear displacement during acceleration, constant speed and deceleration phases, thereby changing the valve opening of the scramjet direct-drive test flow control valve.

[0047] S5, Status Feedback and Monitoring The lower computer 2 collects the actual position and output torque of the servo motor 4 and the valve opening feedback signal of the test flow control valve of the supercharger direct-drive engine in real time, and assembles a status data packet according to a custom communication protocol format. The status data packet is then periodically uploaded to the upper computer 1. The upper computer 1 parses, displays and stores the received status data packet. The custom communication protocol format includes at least the device number, function code, opening command, timing time, timing opening, real-time operating parameters and alarm flag fields.

[0048] S6. Fault Diagnosis and Alarm The host computer 1 and / or the slave computer 2 compare the actual position, output torque and expected value in real time, and monitor the operation status and communication link of the control system of the scramjet direct-drive engine test flow control valve; when any parameter exceeds the preset safety range or communication is abnormal, the specific fault alarm information is immediately triggered and displayed on the human-machine interface of the host computer 1, so as to realize the control of the scramjet direct-drive engine test flow control valve.

[0049] The control principle of the control system for the flow regulating valve in the scramjet direct-drive engine test of this invention is as follows: The opening degree of the flow regulating valve in the scramjet direct-drive engine test is controlled by the lower-level machine 2 controlling the servo motor 4. The servo motor 4 drives the electric cylinder 6 to move forward and backward. Similar to conventional flow regulating valves, the lower-level machine 2 receiving an opening command value of 4 indicates that the flow regulating valve is completely closed; receiving an opening command value of 20 indicates that the flow regulating valve is completely open. The opening feedback of the flow regulating valve is a voltage signal: 1V represents closed (0% opening), 5V represents open (100% opening), and the rest are linear correspondences. When the motor driver 3 receives a pulse signal, it drives the servo motor 4 to rotate a fixed angle in a set direction. The rotation of the servo motor 4 is a step-by-step operation at a fixed angle. The angular displacement can be controlled by controlling the number of pulses, thereby achieving accurate positioning. At the same time, the speed and acceleration of the servo motor 4 can be controlled by controlling the pulse frequency, thereby achieving speed regulation. The lower-level machine 2 converts the flow control valve opening control data into the displacement control of the servo motor 4. Through acceleration, constant speed, and deceleration processes, the flow control valve opening is precisely controlled.

[0050] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the present invention.

Claims

1. A control system for a flow control valve used in a scramjet direct-drive engine test, characterized in that: It includes a host computer (1), a slave computer (2), a motor driver (3), a servo motor (4), and a motion cylinder (6); The host computer (1) is connected to the slave computer (2) for generating and sending control data packets containing a single target opening instruction or timing instruction to the slave computer (2), and receiving, parsing, displaying and storing status data packets from the slave computer (2); The lower-level machine (2) is provided with a data acquisition input terminal and a pulse control signal output terminal; the pulse control signal output terminal is electrically connected to the control signal input terminal of the motor driver (3) and is used to receive and parse the control data packet sent by the upper-level machine (1), generate the corresponding servo control command, and send the servo control command to the motor driver (3). The data output terminal of the motor driver (3) is electrically connected to the control terminal of the servo motor (4) to drive the servo motor (4) to operate; its data input terminal is electrically connected to the encoder feedback terminal of the servo motor (4) to receive encoder data reflecting the operating status of the servo motor (4); a reducer (5) is connected to the output shaft of the servo motor (4); the output shaft of the reducer (5) is connected to the input terminal of the motion cylinder (6); the output terminal of the motion cylinder (6) is used to connect to the valve stem of the scramjet direct-drive engine test flow control valve, so as to adjust the valve opening of the scramjet direct-drive engine test flow control valve by the displacement of the output terminal of the motion cylinder (6); The input terminal of the lower-level machine (2) is electrically connected to the data output terminal of the motor driver (3) and the valve opening sensor of the supercharger direct-drive engine test flow control valve, respectively, so as to collect data on the operating status of the servo motor (4) from the motor driver (3) and the valve opening feedback data from the valve opening sensor in real time.

2. The control system for the flow control valve in a scramjet direct-drive engine test according to claim 1, characterized in that: The host computer (1) includes a unit test module (11), a data storage module (12), a data processing module (13), a communication module (14), a timing module (15), a data display module (16), a timing editing module (17), and a timing verification module (18). The communication module (14) is electrically connected to the lower-level machine (2) through an Ethernet physical interface. It is used to encapsulate and send control data packets to the lower-level machine (2), and at the same time receive and decode status data packets from the lower-level machine (2). The input end of the data processing module (13) is electrically connected to the output end of the communication module (14), and is used to parse, verify, convert units and calculate engineering values ​​of the decoded status data packets to obtain processed real-time data and system events; the output end of the data processing module (13) is electrically connected to the first input end of the data storage module (12) and the first input end of the data display module (16), respectively, and the data storage module (12) is used to store real-time data and system events in a predefined format; The second and third input terminals of the data display module (16) are electrically connected to the output terminal of the data storage module (12) and the first output terminal of the timing module (15), respectively, to call the real-time data of the data processing module (13) and the historical data of the data storage module (12), and display the flow rate, opening degree, torque, pressure and system status parameters in the form of curves, values ​​and dashboards, and refresh the interface periodically; The output of the unit test module (11) is electrically connected to the first input of the communication module (14) and is used to send a control data packet containing a single target opening instruction to the lower computer (2) through the communication module (14). The output of the timing editing module (17) is electrically connected to the second input of the data storage module (12) and the input of the timing verification module (18), respectively, and is used to send the test timing instructions created by the timing editing module (17) to the timing verification module (18) and store them in the data storage module (12). The output of the timing verification module (18) is electrically connected to the input of the timing module (15) and is used to send the timing instructions verified by the timing verification module (18) to the timing module (15); the second output of the timing module (15) is electrically connected to the second input of the communication module (14) and is used to periodically send control data packets containing timing instructions to the lower computer (2).

3. The control system for the flow control valve in a scramjet direct-drive engine test according to claim 2, characterized in that: The lower-level machine (2) includes a data acquisition module (21), a servo motor drive module (22), a network communication module (23), a timer interrupt module (24), an opening degree calculation output module (25), an initialization module (26), and an alarm output module (27). The initialization module (26) is used to configure the hardware ports and initial parameters of the data acquisition module (21), servo motor drive module (22), network communication module (23), timer interrupt module (24), opening degree calculation output module (25) and alarm output module (27) once when the system is powered on. The network communication module (23) is connected to the communication module (14) of the host computer (1) via an Ethernet interface, forming a communication channel for data uplink and downlink. The input terminal of the data acquisition module (21) is electrically connected to the motor driver (3) and the valve opening sensor of the scramjet direct-drive engine test flow control valve, respectively, for real-time acquisition of the actual position, output torque of the servo motor (4) and the valve opening feedback data of the scramjet direct-drive engine test flow control valve; its output terminal is electrically connected to the first input terminal of the opening calculation output module (25), the first monitoring terminal of the alarm output module (27) and the first input terminal of the network communication module (23), respectively, for providing real-time data; The second input terminal of the opening degree calculation output module (25) is electrically connected to the network communication module (23) to obtain the control parameters in the control data packet and the actual position data of the servo motor (4) collected in real time by the data acquisition module (21), and convert the control parameters and actual position data into servo control commands required to control the servo motor (4); the first output terminal and the second output terminal of the opening degree calculation output module (25) are electrically connected to the input terminal of the servo motor drive module (22) and the second input terminal of the network communication module (23) respectively, to package the status data packet containing the control status to the host computer (1) through the network communication module (23), and send the servo control command to the servo motor drive module (22). The pulse signal output terminal of the servo motor drive module (22) is connected to the control port of the motor driver (3), and the data output terminal of the motor driver (3) is electrically connected to the control terminal of the servo motor (4), which is used to drive the servo motor (4) to move according to the servo control command issued by the servo motor drive module (22). The second monitoring terminal of the alarm output module (27) is electrically connected to the third output terminal of the opening calculation output module (25) and is used to determine whether there is a fault based on the monitored data; its alarm information output terminal is electrically connected to the third input terminal of the network communication module (23) and is used to package the alarm information when there is a fault into a status data packet through the network communication module (23) and upload it to the host computer (1). The output terminal of the timer interrupt module (24) is electrically connected to the control terminals of the data acquisition module (21), the opening degree calculation output module (25), and the alarm output module (27), respectively, to trigger periodic scheduling instructions to schedule the data acquisition module (21), the opening degree calculation output module (25), and the alarm output module (27) to execute periodically.

4. The control system for the flow control valve in a scramjet direct-drive engine test according to claim 3, characterized in that, It also includes external alarm devices; The alarm output module (27) is also provided with a local alarm output terminal, which is electrically connected to the control terminal of the external alarm device.

5. A control method for a flow control valve used in a scramjet direct-drive engine test, characterized in that, Includes the following steps: S1. Assemble the control system for the test flow control valve of any one of claims 1-4; S2. Start the control system for the flow control valve used in the scramjet direct-drive engine test, perform system initialization and zero-position positioning, and set the safety range of each operating parameter; S3, Command Issuance and Parsing The host computer (1) sends a control data packet containing a single target opening instruction or timing instruction to the slave computer (2) through a custom communication protocol format according to the test requirements of the scramjet direct-drive engine; the slave computer (2) receives the control data packet and performs verification and parsing to extract the control parameters; S4. Control Command Generation The lower-level machine (2) converts the control parameters obtained by parsing the control data packet into servo control instructions containing the total number of pulses and frequency required to control the servo motor (4); S5, Motion Execution The lower computer (2) sends a servo control command to the motor driver (3); thereby the motor driver (3) drives the servo motor (4) to move according to the servo control command, and then drives the motion cylinder (6) through the reducer (5) to push the valve stem of the supercharged direct-drive engine test flow control valve connected to its output end to produce a linear displacement, thereby changing the valve opening of the supercharged direct-drive engine test flow control valve. S6. Status Feedback and Monitoring The lower computer (2) collects the actual position and output torque of the servo motor (4) and the valve opening feedback signal of the test flow control valve of the supercharger direct-drive engine in real time, and assembles the status data packet according to the custom communication protocol format, and periodically uploads the status data packet to the upper computer (1); the upper computer (1) parses, displays and stores the received status data packet; S7. Fault Diagnosis and Alarm The host computer (1) and / or the slave computer (2) compare the actual position, output torque and expected value in real time, and monitor the operation status and communication link of the control system of the scramjet direct-drive engine test flow control valve. When any parameter exceeds the preset safety range or communication is abnormal, the specific fault alarm information is immediately triggered and displayed on the human-machine interface of the host computer (1) to realize the control of the scramjet direct-drive engine test flow control valve.

6. The control method for the flow control valve in a scramjet direct-drive engine test according to claim 5, characterized in that, Step S2 is as follows: S2.1 Start the control system for the flow control valve used in the scramjet direct-drive engine test and perform system initialization; S2.2, Zero Positioning The servo motor (4) is jogged and fine-tuned. At the same time, test gas is applied to the closed pipe connected to the valve body of the supercharged direct-drive engine test flow control valve connected to the output end of the motion cylinder (6) and the pressure change is monitored. When the pressure change tends to be stable and does not change with the opening and closing of the supercharged direct-drive engine test flow control valve and the slight increase of the intake pressure, the encoder feedback value of the servo motor (4) at this time is recorded and set as the zero position reference of the supercharged direct-drive engine test flow control valve. S2.3 Set the safety range for each operating parameter.

7. The control method for the flow control valve in a scramjet direct-drive engine test according to claim 6, characterized in that: In step S3, the control parameters include the target opening value or the timing opening value; Step S4 is as follows: The lower-level machine (2) will parse the target opening value or timing opening value obtained by the control data packet, and combine it with the preset electromechanical transmission ratio and zero position reference to calculate the target angular displacement of the servo motor (4), and then convert it into a servo control command containing the total number of high-speed pulses and the target pulse frequency required to control the servo motor (4).

8. The control method for the flow control valve in a scramjet direct-drive engine test according to claim 5, characterized in that, Step S5 is as follows: S5.1 The lower computer (2) sends a servo control command containing the total number of high-speed pulses and the target pulse frequency to the motor driver (3); S5.2, Motor driver (3) drives servo motor (4) to rotate in the specified direction and speed according to servo control instructions; S5.3 The torque of the servo motor (4) is amplified by the reducer (5) and then transmitted to the motion cylinder (6). S5.4 The electric cylinder (6) pushes the valve stem of the supercharged direct-drive engine test flow control valve connected to its output end to produce linear displacement in the acceleration, constant speed and deceleration stages, thereby changing the valve opening of the supercharged direct-drive engine test flow control valve.

9. The control method for the flow control valve of a scramjet direct-drive engine test according to any one of claims 5-8, characterized in that: In steps S3 and S6, the custom communication protocol format includes at least the device number, function code, opening command, timing time, timing opening, real-time operating parameters, and alarm flag fields.

10. The control method for a flow control valve used in a scramjet direct-drive engine test according to any one of claims 5-8, characterized in that: In step S4, the lower computer (2) converts the control parameters into the total number of pulses and frequency required to control the servo motor (4) through PTO or PWM.

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