Ship generator load test system and method
By combining intelligent load modules and high-precision sensors, the system achieves efficient, accurate, safe, and reliable load testing of marine generators. It solves the problems of difficulty in simulating complex loads, cumbersome operation, and insufficient safety in traditional methods, and provides comprehensive performance evaluation and fault diagnosis functions.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- JIANGSU XINGYE SHIPBUILDING CO LTD
- Filing Date
- 2026-03-12
- Publication Date
- 2026-05-12
AI Technical Summary
Traditional ship generator load testing methods cannot simulate complex loads, are cumbersome to operate, have poor accuracy, low data acquisition efficiency, and insufficient safety, making it difficult to meet the efficient, accurate, and comprehensive testing requirements of modern ship power systems.
It employs an intelligent load module, a data acquisition and monitoring module, a control and analysis module, and a safety protection module, combined with multiple independently controllable electronic load units, to achieve accurate simulation and automatic control of the load. It is equipped with high-precision sensors and processors for real-time data analysis and has fault diagnosis and safety protection functions.
It enables efficient and accurate load testing, can simulate various load types, improves testing efficiency, reduces manual operation, ensures safety and reliability, and provides performance evaluation and fault diagnosis support.
Smart Images
Figure CN122017559A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of marine generator technology, and in particular to a marine generator load testing system and method. Background Technology
[0002] Marine generators are the heart of a ship's electrical system. Their power quality and reliability directly affect the normal operation of all electrical equipment, including propulsion, navigation, and logistical support systems, thus impacting the ship's overall safety and economy. Therefore, after ship construction, major overhauls, or routine maintenance, rigorous load tests must be conducted on marine generators to verify whether key performance indicators such as output power, voltage and frequency stability, voltage regulation characteristics, and dynamic response meet design and specification requirements.
[0003] Traditional ship generator load tests primarily employ energy-consuming load cells such as water resistors and cast iron resistors. This method has several drawbacks: First, the load type is limited, typically simulating only purely resistive loads, failing to reproduce the inductive and capacitive loads present in actual ship electrical systems. This leads to a disconnect between the test conditions and real-world scenarios, resulting in incomplete evaluation. Second, load adjustment relies on manual switching of resistor plates or adjustment of water resistor plates, which is cumbersome, time-consuming, labor-intensive, and inaccurate. Furthermore, it struggles to achieve continuous and smooth load changes, making precise step or dynamic characteristic tests impossible. Third, data acquisition usually relies on portable instruments and manual readings, which is inefficient, error-prone, and unable to simultaneously capture instantaneous parameters. Data analysis methods are rudimentary, lacking the ability to automatically generate characteristic curves and reports. Finally, traditional load devices are bulky, have poor safety features, and lack comprehensive automatic protection mechanisms.
[0004] With the increasing size and intelligence of ships, power systems are becoming increasingly complex, and the performance requirements for generators are becoming more stringent. Traditional testing methods are no longer sufficient to meet the demands for efficient, accurate, and comprehensive testing. Therefore, there is an urgent need for a modern ship generator load testing system and method that can simulate complex loads, provide automatic control, accurate measurement, intelligent analysis, and is safe and reliable. Summary of the Invention
[0005] The purpose of this invention is to address the shortcomings of existing technologies by proposing a ship generator load testing system and method.
[0006] To achieve the above objectives, the present invention adopts the following technical solution: A marine generator load testing system includes an intelligent load module, a data acquisition and monitoring module, a control and analysis module, and a safety protection module. The intelligent load module includes multiple independently controllable electronic load units for simulating at least one of resistive, inductive, and capacitive loads. The data acquisition and monitoring module is connected to the output terminal of the marine generator and is used to acquire the operating parameters of the marine generator in real time. The control and analysis module is communicatively connected to both the intelligent load module and the data acquisition and monitoring module, and is used to send control commands to the intelligent load module to simulate preset load conditions, and to receive and analyze operating parameters to evaluate generator performance. Both the safety protection module and the data acquisition and monitoring module are connected to the output circuit of the marine generator and are used to provide at least one of overvoltage, overcurrent, and overheat protection based on the operating parameters.
[0007] Preferably, the electronic load unit includes a power switching device, a control circuit, and a heat dissipation device. The control circuit adjusts the power switching device according to the instructions of the control and analysis module to change the size and characteristics of the load. The heat dissipation device is used to dissipate heat from the electronic load unit during operation.
[0008] More preferably, the data acquisition and monitoring module includes at least one of a voltage sensor for acquiring voltage, a current sensor for acquiring current, a frequency sensor for acquiring frequency, and a temperature sensor for acquiring temperature, and also includes a data acquisition card for transmitting and storing the acquired data.
[0009] More preferably, the control and analysis module includes a processor, on which control software and analysis software run. The control software is used to execute a preset test procedure, and the analysis software is used to process the operating parameters, plot the output characteristic curves, and calculate the performance indicators.
[0010] More preferably, the safety protection module includes a protection circuit connected to a voltage sensor, a current sensor, and a temperature sensor. When the detected value exceeds a set threshold, the protection circuit disconnects the electrical connection between the ship's generator and the intelligent load module.
[0011] Preferably, the intelligent load module, data acquisition and monitoring module, control and analysis module, and safety protection module are all connected via fieldbus or industrial Ethernet.
[0012] A method for testing the load of a marine generator, applied to the aforementioned marine generator load testing system, the method comprising the following steps: S1. Pre-test preparation: Conduct a comprehensive inspection of all modules of the ship's generator and load test system to ensure normal function and set the test parameters; S2, No-load test: Start the ship's generator and run it under no-load. The data acquisition and monitoring module collects and records the no-load operation parameters. S3. Load test: The intelligent load control module applies a static load to the ship's generator, the data acquisition and monitoring module collects and records the operating parameters of the ship's generator under different load conditions, and the control and analysis module processes and analyzes the operating parameters. S4. Dynamic Test: The intelligent load control module applies a dynamically changing load to the ship's generator, the data acquisition and monitoring module collects and records the dynamic response parameters of the ship's generator, and the control and analysis module processes and analyzes the dynamic response parameters. S5. Test End: Control the intelligent load module to gradually unload the ship's generator to no load, stop the ship's generator, shut down the load test system, organize the test data and generate a report.
[0013] Preferably, in steps S3 and S4, the parameter analysis of the control and analysis module includes calculating at least one performance indicator among the ship generator's output power, efficiency, voltage regulation rate, and frequency regulation rate.
[0014] More preferably, in step S4, the dynamically changing load includes at least one of a step load, a ramp load, or a sinusoidal load.
[0015] More preferably, during the test, the control and analysis module performs fault diagnosis based on the real-time collected operating parameters, and issues an alarm or triggers the safety protection module when an abnormality is detected.
[0016] The beneficial effects of the present invention are that the ship generator load test system of the present invention is highly efficient. It adopts an intelligent load module, which can quickly and accurately simulate various types and sizes of loads, greatly improving the test efficiency. At the same time, the data acquisition and monitoring module and the control and analysis module have a high degree of automation, reducing manual operation and further improving the test efficiency. The ship generator load test system of the present invention is accurate and comprehensive. The electronic load unit in the intelligent load module has high-precision load control capability and can accurately simulate the load conditions in actual operation. The sensors in the data acquisition and monitoring module have high precision and can collect various operating parameters of the generator in real time and accurately. The control and analysis module can accurately and comprehensively evaluate the performance of the ship generator by conducting in-depth analysis of the collected parameters, providing a strong basis for the optimization and debugging of the generator. The marine generator load test system of the present invention has intelligent control and analysis functions. The control and analysis module can automatically perform load control and data analysis according to the preset experimental process and parameters. The system also has a fault diagnosis function, which can detect generator faults in a timely manner and provide handling suggestions, thus realizing the automation and intelligence of the test process. The marine generator load test system of the present invention has safety and reliability. The safety protection module provides comprehensive safety protection for the test process. Overvoltage protection, overcurrent protection and overheat protection functions can effectively prevent safety accidents caused by abnormal conditions of the generator or load system during the test, and ensure the safety and reliability of the test process. Attached Figure Description
[0017] Figure 1 This is a structural block diagram of a marine generator load testing system according to the present invention; Figure 2 This is a schematic block diagram of a marine generator load testing system according to the present invention; Figure 3 This is a flowchart illustrating the process of a ship generator load test method according to the present invention. Detailed Implementation
[0018] To provide a further understanding of the purpose, structure, features and functions of the present invention, detailed descriptions are provided below with reference to embodiments.
[0019] Please refer to the reference. Figures 1-2 A marine generator load testing system includes an intelligent load module, a data acquisition and monitoring module, a control and analysis module, and a safety protection module. The intelligent load module includes multiple independently controllable electronic load units for simulating at least one of resistive, inductive, and capacitive loads. The data acquisition and monitoring module is connected to the output terminal of the marine generator for real-time acquisition of the generator's operating parameters. The control and analysis module is communicatively connected to both the intelligent load module and the data acquisition and monitoring module, for sending control commands to the intelligent load module to simulate preset load conditions and for receiving and analyzing operating parameters to evaluate generator performance. Both the safety protection module and the data acquisition and monitoring module are connected to the output circuit of the marine generator for overvoltage, overcurrent, and overheat protection based on the operating parameters.
[0020] In some embodiments, the electronic load units of the intelligent load module employ advanced power electronics technology, enabling fast and precise load control. Each electronic load unit includes a power switching device, a control circuit, and a heat dissipation device. The power switching device is used to withstand and regulate the load current; the control circuit adjusts the power switching device according to the instructions of the control and analysis module to change the size and characteristics of the load, thereby simulating resistive, inductive, and capacitive loads and enabling dynamic load changes; the heat dissipation device preferably uses forced air cooling or water cooling to dissipate heat from the electronic load unit during operation, ensuring stable temperature of the electronic load unit during operation and improving its reliability and service life.
[0021] In some embodiments, the data acquisition and monitoring module includes at least one of a voltage sensor for acquiring voltage, a current sensor for acquiring current, a frequency sensor for acquiring frequency, and a temperature sensor for acquiring temperature, preferably a sensor with high accuracy and good stability. The voltage and current sensors are preferably Hall effect sensors or electromagnetic induction sensors, capable of accurately measuring the generator's output voltage and current; the frequency sensor is preferably a digital frequency meter or a phase-locked loop frequency synthesizer, capable of accurately measuring the ship's generator's output power; the module also includes a data acquisition card, which has data acquisition, transmission, and storage functions, capable of converting analog signals acquired from the sensors into digital signals, transmitting them in real time to the control and analysis module for processing and analysis, and storing them for later use.
[0022] In some embodiments, the control and analysis module includes a processor for controlling and coordinating the intelligent load module and the data acquisition and monitoring module, preferably a high-performance microprocessor or an industrial control computer; the processor runs control software and analysis software, the control software is used to execute a preset test procedure, and according to the preset test procedure and parameters, sends control commands to the intelligent load module through a communication interface to achieve precise control of the load; the analysis software is used to perform real-time analysis and processing of the operating parameters of the ship generator transmitted from the data acquisition and monitoring module, plot the output characteristic curve and calculate the performance index.
[0023] In a further embodiment, the control and analysis module also has a fault diagnosis function. The fault diagnosis system is built into the analysis software, including performance qualification criteria, characteristic curve abnormality criteria, etc. It can determine whether there is a fault based on the operating parameters of the ship's generator and provide corresponding fault diagnosis results and handling suggestions.
[0024] In some embodiments, the safety protection module includes a protection circuit, an audible and visual alarm, and a protection actuator. The protection functions of the safety protection module mainly include overvoltage protection, overcurrent protection, and overheat protection. The protection circuit is connected to voltage sensors, current sensors, and temperature sensors. During the load test, the operating status of the ship's generator and load system is monitored in real time. When the output voltage or current of the ship's generator or the temperature of the load system exceeds a set safety threshold, the audible and visual alarm issues an audible and visual warning, or the protection actuator disconnects the electrical connection between the ship's generator and the intelligent load module, ensuring the safety and reliability of the test process.
[0025] In some embodiments, the intelligent load module, data acquisition and monitoring module, control and analysis module, and safety protection module are all connected via fieldbus or industrial Ethernet.
[0026] Please refer to the reference. Figure 3 A method for testing the load of a marine generator, applied to the above-mentioned marine generator load testing system, includes the following steps: S1. Pre-test preparation: Conduct a comprehensive inspection of all modules of the ship's generator and load test system to ensure normal function and set the test parameters; S2, No-load test: Start the ship's generator and run it under no-load. The data acquisition and monitoring module collects and records the no-load operation parameters. S3. Load test: The intelligent load control module applies a static load to the ship's generator, the data acquisition and monitoring module collects and records the operating parameters of the ship's generator under different load conditions, and the control and analysis module processes and analyzes the operating parameters. S4. Dynamic Test: The intelligent load control module applies a dynamically changing load to the ship's generator, the data acquisition and monitoring module collects and records the dynamic response parameters of the ship's generator, and the control and analysis module processes and analyzes the dynamic response parameters. S5. Test End: Control the intelligent load module to gradually unload the ship's generator to no load, stop the ship's generator, shut down the load test system, organize the test data and generate a report.
[0027] In a preferred embodiment, during step S1, the ship's generator is inspected to ensure that its installation and wiring are correct and that the connection between the ship's generator and the ship's power system is reliable; the load test system is inspected to ensure that the functions of each module are normal; when setting test parameters, the parameters include the rated power, rated voltage, rated frequency, load type, and load size of the ship's generator.
[0028] In a preferred embodiment, during step S2, the data acquisition and monitoring module collects and records no-load operating parameters including the no-load voltage, frequency, phase sequence, and other parameters of the ship's generator to ensure that the generator's output is normal.
[0029] In a preferred embodiment, during step S3, a static load point is set; based on the set load type and load size, the intelligent load module is controlled to gradually increase the load, enabling the ship generator to operate under different loads; at each load point, the data acquisition and monitoring module collects parameters such as the generator's output voltage, frequency, power factor, active power, and reactive power in real time, and transmits them to the control and analysis module for processing and analysis; the control and analysis module plots the generator's output characteristic curve based on the collected parameters and analyzes the generator's performance.
[0030] In a preferred embodiment, during step S4, the dynamically changing load mode of the intelligent load module is set, including step load, ramp load, sinusoidal load, etc.; the ship generator is started to operate under dynamic load; the data acquisition and monitoring module measures the dynamic changes of parameters such as the generator's output voltage, frequency, and power factor in real time, and transmits them to the control and analysis module for processing and analysis; the control and analysis module analyzes the dynamic response performance of the generator based on the dynamic parameters.
[0031] In a preferred embodiment, during the test, the control and analysis module first sets warning thresholds and protection thresholds for the output voltage, current, or load system temperature. Based on the real-time collected operating parameters, it performs real-time monitoring and fault diagnosis. When the output voltage, current, or load system temperature exceeds the warning threshold, it issues an audible and visual warning. When the output voltage, current, or load system temperature exceeds the protection threshold or a serious fault is detected, it triggers the protection actuator to disconnect the electrical connection between the ship's generator and the intelligent load module. When an abnormal performance is detected, it analyzes and determines whether a fault exists and provides corresponding fault diagnosis results and handling suggestions.
[0032] This invention discloses a marine generator load testing system that, through the coordinated operation of an intelligent load module, a data acquisition and monitoring module, a control and analysis module, and a safety protection module, achieves efficient, accurate, and automated load testing of marine generators. The experimental system can simulate various types and sizes of loads, collect various operating parameters of the generator in real time, accurately evaluate the generator's performance, and has fault diagnosis and safety protection functions. Compared with traditional marine generator load testing methods, this invention's marine generator load testing method has significant advantages, providing strong support for performance evaluation, fault diagnosis, and optimization debugging of marine generators, and has high practicality and promotional value.
[0033] The present invention has been described in the above-described embodiments; however, these embodiments are merely examples for implementing the present invention. It must be noted that the disclosed embodiments do not limit the scope of the present invention. Conversely, any modifications and refinements made without departing from the spirit and scope of the present invention are within the scope of patent protection of the present invention.
Claims
1. A load testing system for a marine generator, characterized in that, The system includes an intelligent load module, a data acquisition and monitoring module, a control and analysis module, and a safety protection module. The intelligent load module comprises multiple independently controllable electronic load units for simulating at least one of resistive, inductive, and capacitive loads. The data acquisition and monitoring module is connected to the output terminal of the marine generator and is used to acquire the operating parameters of the marine generator in real time. The control and analysis module is communicatively connected to both the intelligent load module and the data acquisition and monitoring module, and is used to send control commands to the intelligent load module to simulate preset load conditions and to receive and analyze operating parameters to evaluate generator performance. Both the safety protection module and the data acquisition and monitoring module are connected to the output circuit of the marine generator and are used to provide at least one of overvoltage, overcurrent, and overheat protection based on the operating parameters.
2. The marine generator load testing system according to claim 1, characterized in that, The electronic load unit includes a power switching device, a control circuit, and a heat dissipation device. The control circuit adjusts the power switching device according to the instructions of the control and analysis module to change the size and characteristics of the load. The heat dissipation device is used to dissipate heat from the electronic load unit during operation.
3. The marine generator load testing system according to claim 1, characterized in that, The data acquisition and monitoring module includes at least one of a voltage sensor for acquiring voltage, a current sensor for acquiring current, a frequency sensor for acquiring frequency, and a temperature sensor for acquiring temperature, and also includes a data acquisition card for transmitting and storing the acquired data.
4. The marine generator load testing system according to claim 1, characterized in that, The control and analysis module includes a processor, on which control software and analysis software run. The control software is used to execute a preset test procedure, and the analysis software is used to process the operating parameters, plot the output characteristic curves, and calculate the performance indicators.
5. A marine generator load testing system according to claim 3, characterized in that, The safety protection module includes a protection circuit, which is connected to a voltage sensor, a current sensor, and a temperature sensor. When the detected value exceeds a set threshold, the protection circuit disconnects the electrical connection between the ship's generator and the intelligent load module.
6. The marine generator load testing system according to claim 1, characterized in that, The intelligent load module, data acquisition and monitoring module, control and analysis module, and safety protection module are all connected via fieldbus or industrial Ethernet.
7. A method for testing the load of a marine generator, applied to the marine generator load testing system as described in any one of claims 1-6, characterized in that, The method includes the following steps: S1. Pre-test preparation: Conduct a comprehensive inspection of all modules of the ship's generator and load test system to ensure normal function and set the test parameters; S2, No-load test: Start the ship's generator and run it under no-load. The data acquisition and monitoring module collects and records the no-load operation parameters. S3. Load test: The intelligent load control module applies a static load to the ship's generator, the data acquisition and monitoring module collects and records the operating parameters of the ship's generator under different load conditions, and the control and analysis module processes and analyzes the operating parameters. S4. Dynamic Test: The intelligent load control module applies a dynamically changing load to the ship's generator, the data acquisition and monitoring module collects and records the dynamic response parameters of the ship's generator, and the control and analysis module processes and analyzes the dynamic response parameters. S5. Test End: Control the intelligent load module to gradually unload the ship's generator to no load, stop the ship's generator, shut down the load test system, organize the test data and generate a report.
8. The method for load testing of a marine generator according to claim 7, characterized in that, In steps S3 and S4, the parameter analysis of the control and analysis module includes calculating at least one performance indicator among the ship generator's output power, efficiency, voltage regulation rate, and frequency regulation rate.
9. A method for load testing of a marine generator according to claim 7, characterized in that, In step S4, the dynamically changing load includes at least one of a step load, a ramp load, or a sinusoidal load.
10. A method for load testing of a marine generator according to claim 7, characterized in that, During the test, the control and analysis module performs fault diagnosis based on the real-time collected operating parameters, and issues an alarm or triggers the safety protection module when an abnormality is detected.