A Mini-Rig test bench based on aircraft hydraulic system and a fault injection method thereof

Abstract

This invention provides a Mini-Rig test bench and its fault injection method based on an aircraft hydraulic system, relating to the field of semi-physical simulation. The test bench includes a semi-physical simulation module, a hydraulic system control unit interface, a data acquisition and playback module, a simulation-real-life switching module, and a fault injection module. The semi-physical simulation module generates input signals for the control unit; the hydraulic system control unit interface connects to the control unit under test; the simulation-real-life switching module switches between semi-physical simulation and full-scale physical operation states; the fault injection function simulates various abnormal operating conditions to verify the control unit's functionality; and the data acquisition and playback module collects and stores the control unit's inputs and outputs and the system status in real time during operation. This invention can efficiently verify the functions and logic of the hydraulic system control unit and implement various fault injection and simulation-real-life switching functions, thereby improving the efficiency and accuracy of hydraulic system control unit testing and verification.

Description

Technical Field

[0001] This invention relates to the field of semi-physical simulation technology, and to a multi-mode test platform structure for verifying the function of hydraulic system control unit, specifically to a hydraulic system Mini-Rig semi-physical simulation test bench that integrates real-simulation switching, fault injection and data playback functions. Background Technology

[0002] As the complexity of aviation hydraulic systems continues to increase, the Hydraulic System Control Unit (HSCU) plays a crucial role in the system's execution logic, anomaly response, and state management. Traditional verification methods for control units mainly rely on physical hydraulic systems for joint debugging, which suffers from problems such as high testing costs, long iteration cycles, uncontrollable fault conditions, and difficulty in reproducing some extreme conditions.

[0003] Physical-to-physical simulation (PHS) technology couples physical control units with simulated hydraulic models in real time, enabling the simulation of various system states under risk-free conditions and achieving comprehensive verification of the control unit's logic, functionality, and fault tolerance. However, existing PHS platforms generally suffer from the following shortcomings:

[0004] 1. Lack of flexible switching capability between physical and simulation systems makes it difficult to quickly build a consistent testing environment between physical and simulation systems.

[0005] 2. Limited fault injection capability: Most platforms cannot simultaneously cover electrical interface faults and hydraulic parameter faults, making it difficult to fully simulate the actual fault scenarios faced by the control unit.

[0006] 3. The test data recording and playback functions are incomplete, making it difficult to achieve traceability analysis and multi-round comparative verification of the control logic.

[0007] Therefore, a comprehensive, scalable, and fully verifiable semi-physical simulation test bench structure is needed to improve the efficiency and accuracy of testing and verification of hydraulic system control units. Summary of the Invention

[0008] In view of this, the present application provides a Mini-Rig test bench based on an aircraft hydraulic system and a fault injection method thereof, which can efficiently verify the function and logic of the hydraulic system control unit and realize various fault injection and simulation switching functions, thereby improving the efficiency and accuracy of hydraulic system control unit testing and verification.

[0009] This application provides the following technical solution: a Mini-Rig test bench based on an aircraft hydraulic system, comprising: The semi-physical simulation module is used to generate input signals for the hydraulic system control unit and output them to the simulation-real-simulation switching module; The simulation switching module has a first input / output terminal connected to the semi-physical simulation module, a second input / output terminal for connecting to an external real hydraulic system device, and a common terminal connected to the control unit under test via a hydraulic system control unit interface. The simulation switching module is used to switch between semi-physical simulation mode and full physical operation mode. The hydraulic system control unit interface is connected between the common terminal of the simulation switching module and the control unit under test for signal transmission. A fault injection module is connected to the signal line of the control unit under test and is used to inject faults into the control unit under test to verify the logic and fault reporting functions of the control unit under test; the fault injection module includes an electrical fault injection unit and a hydraulic fault injection unit. The data acquisition and playback module has its input terminals connected to the input terminal, output terminal, and system status monitoring point of the control unit under test, respectively, and is used to acquire, store, and play back test data.

[0010] According to one embodiment of this application, the electrical fault injection unit is implemented through a circuit breaker test panel and is used to simulate one or more of the following: circuit breaker, grounding, short circuit, and interference signal injection.

[0011] According to one embodiment of this application, the hydraulic fault injection unit simulates hydraulic abnormal output signals by adjusting the state parameters of the real-time simulation model of the hydraulic system in the semi-physical simulation module.

[0012] According to one embodiment of this application, the simulation switching module is composed of a relay matrix and provides hardware-level interlocking protection.

[0013] According to one embodiment of this application, it further includes an HSCU interface conversion module, which is connected in series between the simulation switching module and the control unit under test, and is used to realize signal isolation, level matching and drive buffering.

[0014] According to one embodiment of this application, it further includes a power management module, which uses a programmable power supply to provide controllable power to the test bench and the control unit under test, and is used to simulate power abnormality, voltage drop or power outage fault conditions.

[0015] According to one embodiment of this application, it further includes a host computer and a server; the host computer is communicatively connected to the server, the data acquisition and playback module, and the fault injection module, and is used for test parameter configuration, fault injection setting, real-time data monitoring, and test result display; the server is coupled to the semi-physical simulation module and runs the real-time simulation model of the hydraulic system as a simulation calculation unit to generate hydraulic system response signals under normal and fault conditions.

[0016] This application also provides a fault injection method based on the above-mentioned test bench, including the following steps: Step 1: Switch the test bench to semi-physical simulation mode using the simulation switching module, and connect the control unit under test to the semi-physical simulation module through the hydraulic system control unit interface. Step 2: Run the real-time simulation model of the hydraulic system in the semi-physical simulation module to generate the hydraulic system response signal under normal working conditions and send it to the control unit under test. Step 3: Inject a preset fault into the signal lines of the control unit under test through the fault injection module; Step 4: Collect and store in real time the input data, output data, and system status data of the control unit under test under fault conditions through the data acquisition and playback module; Step 5: Analyze the stored data to verify the control unit's logical judgment and fault reporting functions.

[0017] According to one embodiment of this application, in step three, the preset fault includes one or more of the following: open circuit, grounding, short circuit or interference signals implemented by the electrical fault injection unit, and hydraulic abnormal output signal implemented by the hydraulic fault injection unit by adjusting the state parameters of the simulation model.

[0018] Compared with the prior art, the beneficial effects that the above-mentioned at least one technical solution adopted in the embodiments of this specification can achieve include at least the following: First, the embodiments of the present invention apply semi-physical simulation technology to generate control unit input signals in a virtual environment by establishing a mathematical model of the hydraulic system, thereby realizing control logic and function verification; second, a simulation-real switching module is designed to achieve seamless switching between the semi-physical simulation state and the full physical operation state, improving verification flexibility; third, electrical and hydraulic fault injection methods are proposed to cover open circuit, grounding, short circuit, interference, and abnormal hydraulic output conditions of the control unit interface, realizing full-scenario verification; fourth, data acquisition and playback functions are realized to collect and store the input and output of the control unit and the system status in real time, providing data support for functional verification, fault diagnosis, and anomaly analysis; fifth, the overall solution can efficiently verify the function, logic, and fault handling capabilities of the hydraulic system control unit, and has technical advantages such as high verification efficiency, wide applicability, and good data traceability. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of a Mini-Rig test bench architecture based on an aircraft hydraulic system, according to an embodiment of the present invention. Detailed Implementation

[0021] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0022] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. This application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0023] The "Mini-Rig test bench" described in this invention is a semi-physical simulation platform, typically used for system testing and verification in fields such as aviation. The Mini-Rig test bench is an independent, comprehensive test bench primarily used to support avionics system cross-linking tests, power system equipment flight code verification, and power system testing. It simulates a real-world environment to comprehensively test and verify avionics systems, ensuring system performance and safety.

[0024] This invention provides a Mini-Rig test bench based on an aircraft hydraulic system, comprising: The semi-physical simulation module is used to generate input signals for the hydraulic system control unit and output them to the simulation-real-simulation switching module; The simulation-real-system switching module has a first input / output terminal connected to the semi-physical simulation module, a second input / output terminal for connecting to an external real hydraulic system device, and a common terminal connected to the control unit under test via a hydraulic system control unit interface. The simulation-real-system switching module is used to switch between semi-physical simulation mode and full physical operation mode. In this embodiment, the simulation-real-system switching module is composed of a relay matrix and provides hardware-level interlock protection. The hydraulic system control unit interface is connected between the common terminal of the simulation switching module and the control unit under test for signal transmission. A fault injection module, connected to the signal line of the control unit under test, is used to inject faults into the control unit under test to verify its logic and fault reporting functions. The fault injection module includes an electrical fault injection unit and a hydraulic fault injection unit. In this embodiment, the electrical fault injection unit is implemented through a circuit breaker test panel and is used to simulate one or more of the following: circuit breaker, grounding, short circuit, and interference signal injection. The hydraulic fault injection unit simulates abnormal hydraulic output signals by adjusting the state parameters of the real-time simulation model of the hydraulic system in the semi-physical simulation module. The data acquisition and playback module has its input terminals connected to the input terminal, output terminal, and system status monitoring point of the control unit under test, respectively, and is used to acquire, store, and play back test data. An HSCU interface conversion module is connected in series between the simulation switching module and the control unit under test, and is used to achieve signal isolation, level matching and drive buffering. The power management module uses a programmable power supply to provide controllable power to the test bench and the control unit under test, and is used to simulate power abnormality, voltage drop or power failure conditions. The host computer and server are connected in communication with the server, data acquisition and playback module and fault injection module, and are used for test parameter configuration, fault injection settings, real-time data monitoring and test result display. The server is coupled with the semi-physical simulation module and runs the real-time simulation model of the hydraulic system as a simulation calculation unit to generate hydraulic system response signals under normal and fault conditions.

[0025] The fault injection method for the test bench described in this embodiment of the invention includes the following steps: Step 1: Switch the test bench to semi-physical simulation mode using the simulation switching module, and connect the control unit under test to the semi-physical simulation module through the hydraulic system control unit interface. Step 2: Run the real-time simulation model of the hydraulic system in the semi-physical simulation module to generate the hydraulic system response signal under normal working conditions and send it to the control unit under test. Step 3: Inject a preset fault into the signal line of the control unit under test through the fault injection module; wherein, the preset fault includes: one or more of the following: open circuit, grounding, short circuit or interference signals implemented by the electrical fault injection unit, and hydraulic abnormal output signals implemented by the hydraulic fault injection unit by adjusting the state parameters of the simulation model; Step 4: Collect and store in real time the input data, output data, and system status data of the control unit under test under fault conditions through the data acquisition and playback module; Step 5: Analyze the stored data to verify the control unit's logical judgment and fault reporting functions.

[0026] like Figure 1 As shown, in one specific embodiment, a Mini-Rig test bench based on an aircraft hydraulic system includes: (1) Host computer: monitoring system, used for test parameter configuration, hydraulic model fault injection setting, real-time data monitoring, test result recording and visualization; (2) Server: As a simulation calculation unit, it runs the real-time simulation model of the hydraulic system and generates hydraulic system response signals under normal and fault conditions; (3) Wiring module: including simulation switching module, which realizes the switching between simulation signals and real hydraulic system equipment circuit signals through relay matrix, and provides hardware-level interlock protection; (4) HSCU interface conversion module: realizes signal isolation, level matching and drive buffering, and is used to ensure electrical compatibility and safety between the simulation model output and the HSCU input; (5) Hydraulic System Control Unit (HSCU): The controlled device under test, responsible for executing the hydraulic system control algorithm, status management and diagnostic logic; (6) Electrical Fault Injection Module: Used to simulate electrical faults in various input and output circuits of HSCU, including open circuit, grounding, short circuit and interference signal injection; (7) Power management module: The programmable power supply provides controllable power to the Mini-Rig test bench and HSCU, and can simulate fault conditions such as power abnormality, voltage drop, and power failure.

[0027] The host computer serves as the monitoring system, used for configuring test parameters, setting hydraulic model fault injection, real-time data monitoring, and recording and visualizing test results. The host computer communicates with the server. As the human-machine interface, the host computer is responsible for the overall control of the experiment, including configuring the parameters of the semi-physical simulation model, setting the type and timing of fault injection, real-time monitoring of test data, and post-experiment data analysis and display. The server, as the core computing unit, internally runs a real-time simulation model based on the physical characteristics of a real hydraulic system. This model can accurately simulate the dynamic response of components such as hydraulic pumps, valves, and actuators under normal and preset fault conditions, and generate corresponding pressure, flow, and temperature signals.

[0028] The server, acting as a simulation computing unit, is coupled to the semi-physical simulation module to run a real-time simulation model of the hydraulic system, generating hydraulic system response signals under normal and fault conditions. The simulation signals generated by the server are output to the wiring module. The wiring module integrates a simulation-real-system switching module, the core of which is a controlled relay matrix. One end of this relay matrix connects to the simulation signal output by the server, while the other end has a reserved interface for connecting to real hydraulic system equipment. Under software command control, the relay matrix can quickly and reliably switch the HSCU's input signal channels between "simulation signals" and "real equipment signals." To ensure operational safety, the module also incorporates hardware-level interlocking logic to prevent switching under energized or erroneous conditions, thus avoiding equipment damage.

[0029] HSCU Interface Conversion Module: Connected between the simulation switching module and the HSCU, this module performs signal isolation, level matching, and drive buffering to ensure electrical compatibility and safety between the simulation model output and the HSCU input. The signal selected by the simulation switching module is then transmitted to the HSCU Interface Conversion Module. Since the simulation signal output from the server may be incompatible with the input interface of the real HSCU, the HSCU Interface Conversion Module is responsible for signal isolation, level conversion, and drive buffering to ensure the accuracy and electrical safety of signal transmission.

[0030] The processed signal enters the HSCU of the object under test. The HSCU executes its internal control algorithm based on the received signal and outputs corresponding control commands.

[0031] During testing, the electrical fault injection module is connected in series or parallel to the electrical wiring between the HSCU and external devices (such as actual hydraulic valves, sensors, or HSCU interface conversion modules). This module includes a programmable open-circuit test panel that can accurately simulate various electrical faults according to instructions from the host computer, such as disconnecting the line (open circuit), connecting the line to power or ground (short circuit / ground), or superimposing specific interference signals, thereby verifying whether the HSCU's interface diagnostic circuit can correctly detect and report faults.

[0032] This test bench can also be used to simulate hydraulic faults. Hydraulic faults are not caused by physically damaging the hydraulic lines, but rather by dynamically modifying the parameters of the hydraulic system simulation model running on the server via a host computer. For example, parameters such as "increased internal leakage coefficient" or "decreased oil viscosity" can be set in the model to cause abnormal pressure signals, thus simulating real hydraulic system faults. Upon receiving the abnormal signal, the HSCU's internal fault diagnosis logic identifies and triggers corresponding fault reports or protection actions.

[0033] The data acquisition and playback module collects and stores all key signals in real time, including the HSCU's input signals, output commands, and status feedback from the simulation model or real equipment.

[0034] The power management module employs a high-precision programmable power supply to provide a stable operating voltage for the entire test bench and the HSCU under test. Simultaneously, under the control of the host computer, the power management module can simulate abnormal operating conditions of the aircraft power system, such as voltage dips, momentary power outages, overvoltage / undervoltage, etc., to verify the operational stability of the HSCU under non-ideal power supply conditions.

[0035] The hydraulic system Mini-Rig test bench provided in this invention includes a semi-physical simulation module, a hydraulic system control unit interface, a data acquisition and playback module, a simulation-real-system switching module, and a fault injection module. The semi-physical simulation module establishes a mathematical model of the hydraulic system and generates input signals for the control unit. The hydraulic system control unit interface connects to the control unit under test, enabling signal transmission and feedback. The simulation-real-system switching module switches between semi-physical simulation and full physical operation states to meet different verification requirements. The fault injection function includes electrical fault injection and hydraulic fault injection, used to simulate various abnormal operating conditions to verify the control unit's functions. Electrical fault injection is achieved through a circuit breaker test panel, simulating open circuits, grounding, short circuits, and interference signal injection at each interface circuit of the control unit. Hydraulic fault injection simulates abnormal output signals of the hydraulic system by adjusting the state parameters of the hydraulic system simulation model, thereby verifying the control unit's logical judgment and fault reporting functions. The data acquisition and playback module collects, stores, and replays the control unit's inputs and outputs and system status in real time during operation, providing data support for verification and analysis, and supporting functional verification and anomaly analysis.

[0036] Through the above-described embodiments, the present invention can realize the functional verification, logic testing, fault diagnosis, and data traceability of hydraulic system control units, thereby improving testing efficiency and safety.

[0037] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A Mini-Rig test bench based on an aircraft hydraulic system, characterized in that, include: The semi-physical simulation module is used to generate input signals for the hydraulic system control unit and output them to the simulation-real-simulation switching module; The simulation switching module has a first input / output terminal connected to the semi-physical simulation module, a second input / output terminal for connecting to an external real hydraulic system device, and a common terminal connected to the control unit under test through a hydraulic system control unit interface. The simulation switching module is used to switch between semi-physical simulation mode and full physical operation mode. The hydraulic system control unit interface is connected between the common terminal of the simulation switching module and the control unit under test for signal transmission. A fault injection module is connected to the signal line of the control unit under test and is used to inject faults into the control unit under test to verify the logic and fault reporting functions of the control unit under test; the fault injection module includes an electrical fault injection unit and a hydraulic fault injection unit. The data acquisition and playback module has its input terminals connected to the input terminal, output terminal, and system status monitoring point of the control unit under test, respectively, and is used to acquire, store, and play back test data.

2. The Mini-Rig test bench based on an aircraft hydraulic system according to claim 1, characterized in that, The electrical fault injection unit is implemented through a circuit breaker test panel and is used to simulate one or more of the following: circuit breaker, grounding, short circuit, and interference signal injection.

3. The Mini-Rig test bench based on an aircraft hydraulic system according to claim 1, characterized in that, The hydraulic fault injection unit simulates abnormal hydraulic output signals by adjusting the state parameters of the real-time simulation model of the hydraulic system in the semi-physical simulation module.

4. The Mini-Rig test bench based on an aircraft hydraulic system according to claim 1, characterized in that, The simulation switching module is composed of a relay matrix and provides hardware-level interlocking protection.

5. The Mini-Rig test bench based on an aircraft hydraulic system according to claim 1, characterized in that, It also includes an HSCU interface conversion module, which is connected in series between the simulation switching module and the control unit under test, and is used to achieve signal isolation, level matching and drive buffering.

6. The Mini-Rig test bench based on an aircraft hydraulic system according to claim 1, characterized in that, It also includes a power management module, which uses a programmable power supply to provide controllable power to the test bench and the control unit under test, and is used to simulate power abnormality, voltage drop or power failure conditions.

7. The Mini-Rig test bench based on an aircraft hydraulic system according to claim 1, characterized in that, It also includes a host computer and a server; the host computer is communicatively connected to the server, the data acquisition and playback module and the fault injection module, and is used for test parameter configuration, fault injection settings, real-time data monitoring and test result display. The server is coupled to the semi-physical simulation module and runs the real-time simulation model of the hydraulic system as a simulation calculation unit, generating hydraulic system response signals under normal and fault conditions.

8. A fault injection method based on the test bench according to any one of claims 1 to 7, characterized in that, Includes the following steps: Step 1: Switch the test bench to semi-physical simulation mode using the simulation switching module, and connect the control unit under test to the semi-physical simulation module through the hydraulic system control unit interface. Step 2: Run the real-time simulation model of the hydraulic system in the semi-physical simulation module to generate the hydraulic system response signal under normal working conditions and send it to the control unit under test. Step 3: Inject a preset fault into the signal lines of the control unit under test through the fault injection module; Step 4: Collect and store in real time the input data, output data, and system status data of the control unit under test under fault conditions through the data acquisition and playback module; Step 5: Analyze the stored data to verify the control unit's logical judgment and fault reporting functions.

9. The fault injection method according to claim 8, characterized in that, In step three, the preset faults include: one or more of the following: open circuit, grounding, short circuit or interference signals implemented by the electrical fault injection unit, and hydraulic abnormal output signals implemented by the hydraulic fault injection unit by adjusting the state parameters of the simulation model.

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