Multi-variable decoupling control system for circulating air flow velocity and temperature in incubator

Abstract

The present application relates to the field of environmental control and automation control technology, in particular to a multi-variable decoupling control system for the circulating air flow velocity and temperature in a temperature box; comprising an environmental data acquisition terminal, a multi-variable control server, a fluid execution terminal and a thermodynamic execution terminal; acquiring the circulating air flow velocity data and the flow field temperature data in the box, extracting the transient dynamic characteristics representing the variation rates of the two over time, and when the calculated transient disturbance frequency is greater than or equal to a preset threshold and cross-coupling disturbance triggering is detected, outputting fluid feedforward compensation instructions and heat source feedforward compensation instructions respectively; at the same time, taking the absolute value of the time difference between the preset heat capacity response delay time and the preset flow field pressure building time as the compensation time domain peak shaving phase shift output, so that the thermodynamic execution terminal inserts a delay start time difference to execute the heat load adjustment response, thereby reducing the high frequency confrontation of the actuator and the instability risk of the field quantity in the box.

Description

Technical Field

[0001] This invention relates to the field of environmental control and automation control technology, specifically to a decoupled control system for the multivariable circulating airflow speed and temperature inside a temperature chamber. Background Technology

[0002] During high and low temperature alternating tests on test components such as power battery modules in environmental test chambers, the circulating airflow speed and flow field temperature inside the chamber jointly affect the heat exchange state of the test space. Changes in the heat load of the test components, tooling obstruction, and changes in the airflow guiding structure further affect the stability of the airflow and temperature fields inside the chamber. In traditional methods, the fan and heating or cooling components are usually controlled independently using single-loop control. Under sudden heat loads or local wind resistance changes, the fan speed regulation and temperature regulation are prone to coupling interference, resulting in excessive overshoot in the fan speed control loop and lag compensation in the temperature control loop. This leads to increased local temperature differences inside the chamber, frequent actuator operation, and the system control stability remains low. Summary of the Invention

[0003] The purpose of this invention is to provide a decoupled control system for the circulating air velocity and temperature within an incubator, thereby solving the following technical problems:

[0004] To avoid the problems of mutual interference between wind speed and temperature actions, widening of local temperature difference, and high-frequency resistance of actuators under conventional single-loop control, and through time-domain peak shifting mechanism and dynamic relaxation of error tolerance, wind speed regulation and heat load regulation are transformed from mutual competition to coordinated transition, thereby effectively suppressing compensation overshoot, reducing the dissipation of the execution network, and improving the overall durability and long-term operational stability of the equipment.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] The multivariable decoupled control system for circulating air velocity and temperature inside the incubator includes: an environmental data acquisition terminal, a multivariable control server, a fluid actuator terminal, and a thermodynamic actuator terminal;

[0007] Among them, the environmental data acquisition terminal is used to acquire the current working status data of the physical space inside the preset box, and send the current working status data to the multivariable control server. The current working status data includes circulating airflow velocity data and flow field temperature data.

[0008] The multivariable control server is used to extract transient dynamic features that characterize the rate of change of circulating airflow velocity data and flow field temperature data over time based on the current working state data. When the transient disturbance frequency calculated based on the current working state data is greater than or equal to the preset disturbance frequency band separation threshold, thus detecting the triggering of cross-coupling disturbance, it sends a fluid feedforward compensation command to the fluid execution terminal and a heat source feedforward compensation command to the thermodynamic execution terminal.

[0009] Additionally, the preset thermal capacity response hysteresis time and preset flow field pressure build-up time are obtained from the physical response inertial database embedded in the multivariable control server, and the absolute value of the time difference between the two is output to the thermodynamic execution terminal as the compensation time-domain peak shift amount.

[0010] The fluid actuator terminal is used to receive fluid feedforward compensation commands and respond to fluid wind pressure regulation.

[0011] The thermodynamic execution terminal is used to receive the heat source feedforward compensation command and insert a delayed start-up time difference based on the compensation time domain staggered phase shift amount to execute the thermal load adjustment response.

[0012] Furthermore, the multivariable control server is used to calculate transient disturbance frequencies and detect cross-coupling disturbance triggers in the following ways:

[0013] Retrieve thermodynamic and fluid baseline reference state data from the preset storage space of the multivariable control server;

[0014] By comparing the baseline reference state data with the current operating state data, the difference between the circulating airflow velocity data and the flow field temperature data and the baseline data is calculated, and the state fluctuation frequency band characteristics representing the changes in wind speed deviation amplitude and temperature deviation amplitude over time are generated.

[0015] The transient disturbance frequency of the current input fluctuation is calculated by performing time-frequency domain transformation on the frequency band characteristics of the state fluctuation.

[0016] In response to a transient disturbance frequency being greater than or equal to a preset disturbance frequency band separation threshold, the preset disturbance frequency band separation threshold is used as the reference threshold for the current system judgment. Identification information is written to the system instruction register, and it is determined that a cross-coupling disturbance trigger has been detected.

[0017] Alternatively, in response to a transient disturbance frequency being less than a preset disturbance band separation threshold, the system instruction register's identification information is cleared, and it is determined that no cross-coupling disturbance trigger has been detected.

[0018] Furthermore, multivariate control servers are also used for:

[0019] If it is determined that a cross-coupling disturbance has been detected, the target multidimensional control deviation matrix, which is composed of wind speed deviation amplitude and temperature deviation amplitude, is determined by mapping the current working status data. The row dimension of the target multidimensional control deviation matrix corresponds to different regions of the preset physical space inside the box, and the column dimension corresponds to the wind speed deviation amplitude and temperature deviation amplitude.

[0020] The target multidimensional control deviation matrix is ​​deconstructed by matrix eigenvalue decomposition to calculate the relaxed error tolerance value used to reduce the actuator action reversal frequency.

[0021] Extract the relaxed error tolerance value and directly configure the extracted relaxed error tolerance value as the elastic decoupling relaxation coefficient.

[0022] Furthermore, multivariate control servers are also used for:

[0023] Combining the current working status data and the elastic decoupling relaxation coefficient, the elastic decoupling relaxation coefficient is substituted as the state relaxation boundary condition into the multivariable decoupling control matrix pre-configured by the multivariable control server for matrix multiplication to generate dynamic recombination parameters;

[0024] Based on the dynamic recombination parameters, compensation gain amplitudes adapted to the fluid execution terminal are generated as fluid feedforward compensation commands.

[0025] Based on the dynamic recombination parameters, compensation power biases adapted to the thermodynamic execution terminal are generated as heat source feedforward compensation commands.

[0026] Specifically, the compensation time-domain peak shift amount output by the multivariable control server to the thermodynamic execution terminal is obtained by acquiring the preset thermal capacity response hysteresis time and the preset flow field pressure build-up time recorded in the physical response inertial database embedded in the multivariable control server, and calibrating the absolute value of the time difference between the two.

[0027] Furthermore, multivariate control servers are also used for:

[0028] Set up the mobile data calculation window used for statistical data;

[0029] Simultaneously monitor and statistically analyze the control command reversal rate data of fluid actuators and thermodynamic actuators due to compensation intervention within the mobile data calculation window;

[0030] Monitor and record the dead zone dwell time data of the thermodynamic execution terminal when it is in the dead zone state range.

[0031] Furthermore, multivariate control servers are also used for:

[0032] By multiplying the control command reversal rate data with a first preset weight and summing the product of the inverse of the dead zone dwell time data and a second preset weight, an execution network dissipation index characterizing the degree of mechanical fatigue accumulation of the actuator is generated.

[0033] Obtain the preset device durability loss threshold;

[0034] In response to the network dissipation index being greater than or equal to the preset device durability loss threshold, the output compensation time-domain phase shift is incremented to expand the action time interval.

[0035] Alternatively, in response to the network dissipation index being less than a preset device durability loss threshold, the compensation time-domain phase shift of the current output is maintained to preserve the action time interval.

[0036] Furthermore, the environmental data acquisition terminal includes: a wind speed sensing module and a temperature sensing distribution node group;

[0037] Among them, the wind speed sensing module is used to collect the internal wind pressure distribution of the physical space inside the preset box as a component of the circulating airflow speed data;

[0038] The temperature sensing distribution node group is used to collect the internal spatial temperature gradient of the physical space inside the preset box as a component of the flow field temperature data.

[0039] Furthermore, the fluid actuator includes a duct power assembly with a variable frequency drive; the thermodynamic actuator includes a heat source and cold source conversion assembly with a power regulation interface.

[0040] Among them, the duct power component is used to convert the received fluid feedforward compensation command into a change in wind pressure.

[0041] The heat source and cold source conversion component is used to convert the received heat source feedforward compensation command into a heating or cooling power adjustment amount through electrothermal conversion behavior.

[0042] Furthermore, the multivariable decoupling control system also includes a front-end monitoring and interaction terminal; the front-end monitoring and interaction terminal is used for:

[0043] Receive the frequency band characteristics of state fluctuations and the compensated time-domain phase shift amount forwarded by the multivariable control server;

[0044] The received state fluctuation frequency band characteristics and the compensated time domain peak phase shift are visualized and the alarm threshold is exceeded.

[0045] Furthermore, the number of environmental data acquisition terminals, fluid execution terminals, and thermodynamic execution terminals is set to at least one.

[0046] The beneficial effects of this invention are:

[0047] 1. This invention extracts the transient dynamic characteristics of circulating airflow velocity and flow field temperature, and when cross-coupling disturbance is detected, sends a feedforward command with a time-domain staggered phase shift compensation to the execution terminal. This mechanism utilizes the difference between heat capacity and the objectively existing response hysteresis of the fluid to perform staggered actions, transforming the traditional competitive regulation into a sequential and coordinated transition, effectively avoiding the chain interference and local temperature difference expansion caused by the simultaneous action of wind pressure and temperature.

[0048] 2. This invention utilizes a server to acquire benchmark reference state data and compares it with the current state. After generating state fluctuation frequency band characteristics, it performs time-frequency domain conversion to solve the transient disturbance frequency. This mechanism can accurately distinguish between the slow temperature drift during normal operation of the test chamber and the sudden cross-coupling disturbance that needs to be quickly addressed, avoiding the control system from performing full-gain closed-loop compensation for all conventional parameter changes, thereby significantly reducing unnecessary mechanical resistance and energy consumption.

[0049] 3. After triggering the disturbance, this invention deconstructs the multidimensional control deviation matrix through matrix eigenvalue decomposition, calculates the elastic decoupling relaxation coefficient, and substitutes it into the control matrix to generate dynamic recombination parameters. This mechanism introduces a state-dependent elastic boundary, no longer forcibly compressing transient deviations with a single rigid matrix, but dynamically relaxes part of the error tolerance according to the dominant coupling mode, which significantly suppresses the compensation overshoot phenomenon and enhances the control stability under complex test component loading conditions.

[0050] 4. This invention generates an execution network dissipation index that characterizes the wear state of the system by statistically analyzing the control command flip rate and dead zone dwell time data within the mobile calculation window; when the mechanical fatigue risk is identified to reach the equipment durability loss threshold, the system will adaptively expand the compensation time domain staggered phase shift amount, and incorporate control quality and physical component life into the closed loop at the same time, actively avoiding the exchange of excessively frequent actions for temporary stability, thereby improving the long-term operational stability of the whole machine.

[0051] 5. This invention uses a temperature distribution node group and a multi-point wind speed sensing module to obtain the internal space temperature gradient and wind pressure distribution, and is combined with an execution component with variable frequency drive and power regulation capabilities. This mechanism greatly improves the ability to perceive spatial non-uniform features such as local flow obstruction in the box, so that the control input includes local gradient features, ensuring that complex multivariable feedforward compensation commands can be accurately, continuously and smoothly implemented by the underlying physical devices. Attached Figure Description

[0052] The invention will now be further described with reference to the accompanying drawings.

[0053] Figure 1 This is a module architecture diagram of the decoupled control system for the circulating airflow velocity and temperature in the incubator in this embodiment of the application. Detailed Implementation

[0054] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0055] Please see Figure 1 The multivariable decoupled control system for circulating air velocity and temperature in the incubator includes: an environmental data acquisition terminal, a multivariable control server, a fluid actuator terminal, and a thermodynamic actuator terminal;

[0056] Among them, the environmental data acquisition terminal is used to acquire the current working status data of the physical space inside the preset box, and send the current working status data to the multivariable control server. The current working status data includes circulating airflow velocity data and flow field temperature data.

[0057] The multivariable control server is used to extract transient dynamic features that characterize the rate of change of circulating airflow velocity data and flow field temperature data over time based on the current working state data. When the transient disturbance frequency calculated based on the current working state data is greater than or equal to the preset disturbance frequency band separation threshold, thus detecting the triggering of cross-coupling disturbance, it sends a fluid feedforward compensation command to the fluid execution terminal and a heat source feedforward compensation command to the thermodynamic execution terminal.

[0058] Additionally, the preset thermal capacity response hysteresis time and preset flow field pressure build-up time are obtained from the physical response inertial database embedded in the multivariable control server, and the absolute value of the time difference between the two is output to the thermodynamic execution terminal as the compensation time-domain peak shift amount.

[0059] The fluid actuator terminal is used to receive fluid feedforward compensation commands and perform fluid wind pressure regulation response; the thermodynamic actuator terminal is used to receive heat source feedforward compensation commands and, based on the compensation time domain staggered phase shift, insert a delayed start-up time difference to perform thermal load regulation response.

[0060] This embodiment provides a mechanism for decoupling control of multiple variables of circulating airflow speed and temperature in the chamber; specifically, the unified main scenario is set as follows: a certain power battery module needs to undergo a 48-hour high and low temperature alternating aging test before leaving the factory. The test equipment is an environmental test chamber with a volume of 2 cubic meters; 6 battery modules are placed in the chamber, and the modules will generate sudden thermal load when switching between charging and discharging.

[0061] Meanwhile, due to the obstruction of the fixture and the change in the opening of the baffle inside the chamber, the circulating airflow velocity and temperature distribution will show obvious coupling. If the fan and heating / cooling components are controlled separately in a conventional single-loop manner, transient overshoot of the wind speed loop, response lag of the temperature loop, and dynamic coupling interference between the two types of actuators often occur, resulting in an expansion of the local temperature difference inside the chamber, frequent speed increase and decrease of the fan, and repeated start and stop of the heat source.

[0062] In this scenario, the environmental data acquisition terminal is placed inside the test chamber to continuously collect current working status data. This data includes at least two types: one is circulating airflow velocity data, and the other is flow field temperature data. After receiving this data, the multivariable control server does not directly perform rigid simultaneous strong compensation, but first extracts transient dynamic characteristics.

[0063] The transient dynamic characteristics here can be understood as the trend, magnitude, and rate of change of wind speed and temperature within a short time window. For example, in four consecutive sampling times t1, t2, t3, and t4, the average wind speeds were monitored to be 2.0 m / s, 2.6 m / s, 2.8 m / s, and 2.7 m / s, respectively, and the average temperatures were 45.0℃, 45.3℃, 45.9℃, and 46.4℃, respectively. The server can then conclude that the wind speed first rises rapidly and then stabilizes, while the temperature continues to rise, indicating a difference in the physical response constants between the fluid control loop and the thermodynamic control loop.

[0064] Transient dynamic features specifically refer to the rate of change vector extracted by performing first-order difference operations on the sampled sequence, and the acceleration features obtained by calculating the second derivative, which are used to quantitatively characterize the slope of a variable deviating from its steady-state trajectory.

[0065] The server calculates the transient disturbance frequency based on the current working status data. To illustrate the technical principle, a typical calculation model is used below: Within a 2-second moving window, samples are taken every 0.5 seconds. If the wind speed deviation sequence is [0.1, 0.6, 0.7, 0.2] and the temperature deviation sequence is [0.2, 0.5, 0.9, 1.1], the server first observes whether the changes in the deviations of the two are concentrated in a short period of time.

[0066] If the main energy of the deviation fluctuation is concentrated in a higher frequency band, it can be determined that there is a sudden disturbance in the current box, rather than a low-frequency quasi-steady-state deviation. Specifically, the higher frequency band refers to the frequency band where the main frequency of the frequency band energy is greater than or equal to the preset disturbance frequency band separation threshold. When the frequency of this transient disturbance is greater than or equal to the preset threshold, it is determined that a cross-coupling disturbance has been triggered. At this time, the server cancels the synchronous response mechanism between the fluid actuator and the thermodynamic actuator, and adjusts the controlled variable with asymmetric frequency or step size. Instead, it outputs two feedforward compensations: one to the fluid actuator for priority adjustment of air pressure; and the other to the thermodynamic actuator for adjustment of thermal load.

[0067] In this embodiment, a compensation time-domain peak shift is specifically introduced; this amount is determined by the absolute value of the time difference between the preset thermal capacity response hysteresis time and the preset flow field pressure build-up time; for example, in actual calibration, it was found that: from the time the fan receives the speed adjustment command to the time the main air duct in the box establishes a stable air pressure, it takes an average of 3 seconds; from the time the heating component receives the power adjustment command to the time the temperature change at the main measuring point in the box exceeds the preset sensitivity threshold, it takes an average of 18 seconds.

[0068] The absolute value of the time difference between the two is 15s, which can be used as the delayed start-up time difference of the thermodynamic execution terminal. Specifically, when a cross-coupling disturbance signal is detected, the server first lets the fan perform fluid feedforward compensation, and the thermodynamic execution terminal starts the corresponding heat source feedforward compensation 15s later. This can avoid applying two strongly coupled actions with large inertial differences at the same time.

[0069] Furthermore, the fluid actuator can be composed of a variable frequency fan and a damper combination, and after receiving the fluid feedforward compensation command, it can adjust the air pressure and main circulation speed in the box; the thermodynamic actuator can be composed of a heater, an evaporator, a solenoid valve and a cooling capacity switching module, and after receiving the heat source feedforward compensation command, it can perform heat load adjustment based on the inserted delayed start time difference.

[0070] As an anomaly handling method, if wind speed data is missing in a certain sampling period but temperature data is complete, the server can use the wind speed change rate of the previous period and reduce the weight of the current disturbance judgment to avoid false triggering due to single-point sampling anomaly; if temperature data is missing but wind speed changes suddenly, fluid feedforward compensation of no more than 20% of rated power can still be output first, while pausing thermodynamic side actions and waiting for temperature data to be recovered; if both types of data are abnormal at the same time, the system enters conservative mode, only maintaining the current execution state and issuing equipment alarms.

[0071] Furthermore, if the absolute value of the calculated time difference does not reach the preset minimum control sampling period, for example, less than or equal to 1s, it is calibrated to 0s and determined to be in synchronous trigger mode; if it is greater than or equal to the upper limit of the allowable delay of the thermodynamic execution terminal, for example, greater than or equal to 60s, it is truncated to 60s to avoid excessive delay causing the temperature control deviation to exceed the preset static error range.

[0072] Within the first 10 seconds after the battery module switched from the static stage to the 1C discharge stage, the local heat load inside the box suddenly increased, and the temperature node near the top of the module rose from 45.0℃ to 46.2℃, while the wind speed in the right area of ​​the guide channel dropped from 2.2m / s to 1.4m / s due to the tooling obstruction.

[0073] Based on this, the server identifies that the transient disturbance has reached the threshold. It first sends a compensation command to the fan to increase the air pressure by 12%, and sends a compensation command to the thermodynamic execution terminal to reduce the heating power by 8%, but the latter is executed with a 15-second delay. In this way, the wind field first tends to be spatially uniformly distributed, and then the heat is released in a controlled manner, avoiding the oscillation of controlled variables caused by the synchronous action of air pressure regulation and heating regulation.

[0074] The purpose of this step is to utilize the objective physical characteristics of fast fluid response and slow thermal response to decouple the coupled control action by phase shift, so that the air speed regulation and heat load regulation in the box are transformed from unsteady competitive response to sequential coordinated response with time margin, thereby reducing the loss of actuators caused by frequent conflict of action directions and the risk of instability of field quantities in the box.

[0075] In a preferred embodiment of the present invention, the multivariable control server is used to calculate the transient disturbance frequency and detect cross-coupling disturbance triggers by: acquiring thermal and fluid reference state data from the preset storage space of the multivariable control server; comparing the reference reference state data with the current operating state data, calculating the difference between the circulating airflow velocity data and the flow field temperature data relative to the reference data, and generating state fluctuation frequency band characteristics characterizing the changes in wind speed deviation amplitude and temperature deviation amplitude over time; performing time-frequency domain transformation on the state fluctuation frequency band characteristics to calculate the transient disturbance frequency of the current input fluctuation;

[0076] In response to a transient disturbance frequency being greater than or equal to a preset disturbance band separation threshold, the preset disturbance band separation threshold is used as the reference threshold for the current system determination. Identification information is written to the system instruction register, and it is determined that a cross-coupling disturbance trigger has been detected. Alternatively, in response to a transient disturbance frequency being less than the preset disturbance band separation threshold, the identification information in the system instruction register is cleared, and it is determined that no cross-coupling disturbance trigger has been detected.

[0077] This embodiment provides a mechanism for calculating transient disturbance frequencies and detecting cross-coupling disturbance triggers; specifically, in the main scenario of the aforementioned battery module aging test chamber, relying solely on the current sampled value to make a threshold judgment can easily misjudge slow temperature rise as sudden coupling disturbance;

[0078] After the battery module has been continuously discharged for 30 minutes, the overall box temperature may rise smoothly by 2°C. This is due to long-term load drift and does not necessarily require entering the multivariable decoupling control mode with delayed triggering characteristics. To avoid this defect, this embodiment introduces a reference state data and time-frequency domain conversion process.

[0079] The baseline reference state data can be pre-stored in the server, representing the thermal and fluid baseline of the test chamber under standard operating conditions. For example, under the operating conditions of chamber temperature 45℃, target wind speed 2.5m / s, baffle opening 60%, and module discharge rate 0.5C, the reference state can be recorded as follows: the average wind speeds of the left, middle, and right zones are 2.4m / s, 2.5m / s, and 2.6m / s, respectively, and the corresponding average temperatures of the three zones are 44.8℃, 45.0℃, and 45.1℃, respectively.

[0080] Once the system collects the current operating status in real time, it compares it with the baseline to obtain the wind speed deviation and temperature deviation. For example, if the actual wind speed in the three zones is [1.8, 2.1, 2.9] and the temperature is [46.0, 45.7, 44.9] during a certain period, the deviation can be mapped to wind speed [-0.6, -0.4, +0.3] and temperature [+1.2, +0.7, -0.2].

[0081] The server further generates frequency band characteristics of state fluctuations; a simplified time series organization method can be used here: at the most recent 8 sampling points, the average absolute value of wind speed deviation is taken to form a sequence V=[0.1, 0.2, 0.7, 0.8, 0.3, 0.2, 0.1, 0.1], and the average absolute value of temperature deviation is taken to form a sequence T=[0.2, 0.3, 0.4, 0.8, 1.0, 1.1, 1.0, 0.9]. According to the changes in this sequence, it can be observed that V increases abruptly at the middle two sampling points, while T rises for a longer period of time, indicating that the disturbance has obvious transient components.

[0082] The transient disturbance frequency of the current input fluctuation is obtained by performing a time-frequency domain transformation on the frequency band characteristics of the state fluctuation. The implementation is not limited to a specific algorithm and can be implemented by short-window discrete transformation, segmented frequency band energy calculation or equivalent engineering implementation. Assuming that the transient disturbance frequency obtained after the transformation is 0.9Hz and the preset disturbance frequency band separation threshold is set to 0.6Hz, it is determined that the cross-coupling disturbance triggering condition has been reached.

[0083] At the level of writing the recognition result, the server uses the threshold as the preset threshold for the current judgment and writes the trigger flag information into the system instruction register, such as writing 1; after the subsequent compensation module reads the flag, it can call the feedforward compensation and time series misalignment logic; conversely, if the transformed main disturbance frequency is only 0.2Hz, it means that the current change is closer to slow drift, so the register flag is cleared, such as writing 0 or directly clearing the field, indicating that the cross-coupling disturbance process is not triggered.

[0084] As an anomaly handling method, if the reference state data does not match the current configuration in the test chamber, for example, the test chamber has been changed from 6 sets of battery modules to 3 sets of high-capacity modules, directly using the old baseline will amplify the error. In this case, the corresponding reference baseline can be automatically switched according to the current tooling number, the batch of the tested part, and the target temperature zone. If a perfectly matching baseline still cannot be found, the baseline of the adjacent operating condition is selected and the trigger threshold is increased to reduce the probability of misjudgment. If there are insufficient sampling points during the time-frequency domain conversion, for example, only 3 points are accumulated and the minimum analysis length has not been reached, the register is not updated temporarily and the previous state is maintained. If the wind speed deviation and temperature deviation are both extremely small, for example, they are all less than the sensor accuracy band in multiple consecutive windows, the state is directly determined to be untriggered to avoid false triggering at the noise level.

[0085] In the same battery module aging test chamber, 20 minutes after the start of a certain test, local dust accumulation on the heat sink of the right module caused a sudden increase in ventilation resistance. The wind speed deviation increased from -0.1m / s to -0.8m / s in a short period of time, while the temperature deviation increased from +0.2℃ to +1.3℃ in the following seconds.

[0086] After comparing the sequence with the baseline state, the server identifies the transient disturbance frequency of 0.85Hz through time-frequency domain conversion, which is higher than the separation threshold of 0.6Hz, and then writes the trigger flag; otherwise, if it is just testing the set temperature to slowly rise from 45℃ to 50℃, its frequency band is mainly concentrated in the low frequency region, and the register remains in the untriggered state.

[0087] The purpose of this mechanism is to distinguish between normal slow changes and coupled disturbances that require rapid compensation and adjustment, so that subsequent peak-shifting compensation only intervenes when it is really needed, thereby avoiding unnecessary execution consumption caused by the system performing high-intensity compensation for all changes.

[0088] Furthermore, to avoid confusion between the frequency characteristics of state fluctuation bands and the frequency of transient disturbances during use, the relationship between the two can be fixed as follows: the former is a set of time-series characteristics formed by the changes of wind speed deviation amplitude and temperature deviation amplitude over time, including at least one or more of the deviation amplitude, rate of change, and frequency band energy distribution.

[0089] The latter is the frequency result used to determine whether a trigger has occurred, obtained by performing a time-frequency domain transformation on the state fluctuation frequency band characteristics. In other words, the state fluctuation frequency band characteristics belong to the upstream analysis object, while the transient disturbance frequency belongs to the downstream determination parameter calculated by the analysis object. The two are not synonymous substitutes.

[0090] Correspondingly, the dominant frequency components of the current input fluctuation mentioned in the text are all used as equivalent expressions of the transient disturbance frequency, and their physical meanings remain consistent. They all refer to the dominant frequency results used for comparison with the disturbance frequency band separation threshold within the current analysis window.

[0091] In this embodiment, the disturbance band separation threshold and the preset threshold maintain a one-to-one correspondence. That is, when the detection path is adopted, the preset threshold is specifically taken as the disturbance band separation threshold. Through the above agreement, the trigger determination, register identifier writing and front-end display object in subsequent embodiments can maintain the same technical semantic chain.

[0092] In a preferred embodiment of the present invention, the multivariable control server is further configured to: upon determining that a cross-coupling disturbance has been detected, determine a target multidimensional control deviation matrix mapped by the current operating state data, consisting of wind speed deviation amplitude and temperature deviation amplitude, wherein the row dimension of the target multidimensional control deviation matrix corresponds to different regions of the preset physical space within the box, and the column dimension corresponds to the wind speed deviation amplitude and temperature deviation amplitude. Specifically, the target multidimensional control deviation matrix is: An order matrix, where Given the number of different regions in the space, the first column of the matrix corresponds to the wind speed deviation amplitude, and the second column corresponds to the temperature deviation amplitude. The target multidimensional control deviation matrix is ​​deconstructed by matrix eigenvalue decomposition to calculate the relaxed error tolerance value used to reduce the actuator action reversal frequency. The relaxed error tolerance value is extracted and directly configured as the elastic decoupling relaxation coefficient.

[0093] The multivariable control server is also used to: combine the current working state data and the elastic decoupling relaxation coefficient, substitute the elastic decoupling relaxation coefficient as the state relaxation boundary condition into the multivariable decoupling control matrix pre-configured by the multivariable control server to perform matrix multiplication operations, and generate dynamic recombination parameters;

[0094] Based on the dynamic reconfiguration parameters, compensation gain amplitudes adapted to the fluid execution terminals are generated as fluid feedforward compensation commands; based on the dynamic reconfiguration parameters, compensation power biases adapted to the thermodynamic execution terminals are generated as heat source feedforward compensation commands.

[0095] Specifically, the compensation time-domain peak shift amount output by the multivariable control server to the thermodynamic execution terminal is obtained by acquiring the preset thermal capacity response hysteresis time and the preset flow field pressure build-up time recorded in the physical response inertial database embedded in the multivariable control server, and calibrating the absolute value of the time difference between the two.

[0096] This embodiment provides a mechanism for calculating the elastic decoupling relaxation coefficient and generating dynamic recombination parameters based on it after triggering a cross-coupling disturbance; specifically, in the aforementioned main scenario, it is not enough to simply determine that intervention is needed.

[0097] If the compensation amount is still calculated rigidly according to the fixed decoupling matrix, the fan speed will increase significantly and the heat source will decrease significantly at the same time under extreme conditions. High-frequency oscillation feedback or execution logic conflict may still occur between the actuators. Therefore, this embodiment adds a buffer step that allows for a moderate deviation after triggering. That is, the relaxed error tolerance is first obtained and then used as the elastic decoupling relaxation coefficient to participate in the reorganization of the control quantity.

[0098] The construction of the target multidimensional control deviation matrix is ​​explained below. For ease of explanation, the wind speed deviation and temperature deviation inside the chamber can be simplified into two regions and two variables. It is assumed that at the current moment, the wind speed deviation in the left region is -0.6 m / s and the wind speed deviation in the right region is +0.2 m / s; the temperature deviation in the left region is +1.4℃ and the temperature deviation in the right region is +0.5℃.

[0099] This can be organized into a 2×2 matrix, where the first row contains data for the left region [-0.6, +1.4] and the second row contains data for the right region [+0.2, +0.5]. This matrix reflects the deviation coupling relationship of multiple regions and multiple variables at the same time. The server performs a deconstruction operation on this matrix, specifically using eigenvalue decomposition or equivalent matrix principal feature extraction methods, to identify which combination pattern the current deviation is mainly concentrated on.

[0100] If the weight of one principal feature obtained after decomposition is much greater than that of another feature, it indicates that the current disturbance is mainly dominated by a certain coupling mode, thus preventing all actuators from generating full-dimensional synchronous tracking actions. The server extracts the maximum principal eigenvalue obtained after matrix eigenvalue decomposition and calculates the ratio of this maximum principal eigenvalue to the sum of all eigenvalues. Then, it multiplies this ratio by a pre-configured system baseline tolerance coefficient, for example, a value between 0.2 and 0.3, and uses this as a function mapping to calculate a relaxed error tolerance value, for example, 0.18. The specific calculation formula for this function mapping is as follows: ,in, This indicates a relaxed error tolerance value. This represents the pre-configured system baseline tolerance factor. Represents the maximum principal eigenvalue. Represents the matrix decomposition of the first... One characteristic value; this value can be understood as: in this round of transient adjustment, a margin of 18% is allowed for some control deviations to be retained for a short period of time in exchange for the continuity of the actuator control command change rate;

[0101] Furthermore, in engineering deployment, the target multidimensional control deviation matrix is ​​not necessarily limited to 2×2; if the box is divided into 3 regions and only two variables, wind speed and temperature, are considered, the original deviation matrix can be 3×2; if more regions are divided, the matrix may also be in the form of N×2 or N×M.

[0102] At this point, in order to keep the main processing line of deconstructing the target multidimensional control deviation matrix through matrix eigenvalue decomposition unchanged, the server can first retain the region-variable mapping relationship expressed by the original deviation matrix, and then construct a square matrix that is equivalent to it to represent the coupling strength for eigenvalue decomposition.

[0103] For example, a correlation matrix can be constructed from the original deviation matrix A. Or construct when it is necessary to highlight regional connections. The resulting square matrix is ​​decomposed into eigenvalues. The purpose of this is not to change the physical meaning of the target deviation matrix, but to compress the coupled information of multiple regions and multiple variables into the main feature space that can be stably decomposed, thereby avoiding the implementation ambiguity caused by direct decomposition in non-square matrix scenarios.

[0104] To further explain, the original target multidimensional control deviation matrix A obtained by mapping the current working state data can be further constructed to obtain the correlation matrix G; the superscript T in the formula only indicates the matrix transpose operation, does not represent a new temperature variable, and is not confused with the letter T used to represent the temperature deviation sequence in the previous implementation; correspondingly, when using When emphasizing the coupling correlation in the dimension of variables; when adopting At that time, the emphasis was on the coupling correlation in the regional dimension, and both belonged to the equivalent analysis path derived from the original deviation matrix A;

[0105] Correspondingly, after the server extracts the main feature values ​​and their proportions from the relevant matrix, it can map the concentration of the dominant features to the relaxed error tolerance value: the higher the degree of dominance, the more concentrated the current deviation is in a few coupling modes, and the more suitable it is to use a larger relaxation margin to reduce the intense synchronous action of the entire actuator.

[0106] The lower the degree of dominance, the more dispersed the sources of deviation, and the more conservative the relaxation coefficient should be. In this way, regardless of whether the original target multidimensional control deviation matrix is ​​a square matrix or not, the physical meaning of the relaxed error tolerance value remains consistent, that is, it is used to characterize how much short-term residual deviation is allowed to be retained in this round of control in exchange for execution smoothness.

[0107] After extracting the value, it is directly configured as the elastic decoupling relaxation coefficient; the server substitutes the current working status data and the coefficient into the pre-configured multivariate decoupling control matrix, performs matrix multiplication, and generates dynamic recombination parameters.

[0108] Continuing with the simplified derivation: Assume the pre-configured decoupling matrix contains the first row [1.0, -0.3] and the second row [-0.2, 1.0]. This matrix indicates that wind speed control has a suppressive coupling effect on temperature error, and thermal control also has a certain reverse effect on wind speed error. The off-diagonal elements in the decoupling matrix represent cross-coupling coefficients, which are calibrated from the pre-acquired multivariate system identification model of wind speed and temperature inside the chamber. Since locally increased wind speed will accelerate heat exchange and dissipation, resulting in a decrease in temperature, this cross-coupling coefficient is calibrated as a negative value, and thus represents suppressive coupling in the matrix. If the current comprehensive deviation vector is [-0.5, +1.0], the originally calculated compensation vector may be [-0.8, +1.1].

[0109] Now, with the introduction of a relaxation boundary of 0.18, it is equivalent to no longer requiring the complete elimination of all deviations within a single control cycle, but rather relaxing some cross terms, so that the final dynamic recombination parameters can be [-0.65, +0.9]. In engineering terms, this means that the fan gain does not need to reach the preset slope upper limit, and the heat source power bias does not need to immediately reach the rated output power threshold.

[0110] Based on the dynamic recombination parameters, the server generates a compensation gain amplitude adapted to the fluid actuator, such as increasing the frequency of the fan by 9%; at the same time, it generates a compensation power bias adapted to the thermodynamic actuator, such as reducing the heating power by 6% or increasing the opening of the cooling valve by 4%; the compensation time-domain peak shift is read from the calibration results in the physical response inertial database.

[0111] This database can store historical calibration values ​​by equipment model, chamber volume, typical loading rate, etc. For example, for the current 2 cubic meter test chamber with a loading rate of 70%, the database records a flow field pressure build-up time of 3s and a thermal capacity response hysteresis time of 18s, so the peak shift calibration is 15s. If the calibration is changed to an unloaded calibration condition, the values ​​may be 2s and 9s respectively, so the peak shift becomes 7s.

[0112] As an anomaly handling method, if the target multidimensional control deviation matrix exhibits ill-conditioning, such as all rows or columns being 0, leading to unstable decomposition results, the server can switch to a preset simplification mode and directly calculate a conservative relaxation coefficient based on the average wind speed deviation and average temperature deviation, for example, by fixing it at 0.1; if the relaxation error tolerance value obtained from the decomposition is negative or exceeds the upper limit, it will be truncated to between 0 and 1 respectively to ensure that it has a clear physical meaning when used as a relaxation coefficient;

[0113] If the current working status deviates from the database calibration condition by more than the preset confidence interval, such as the loading rate exceeding the database record range, the nearest gear can be selected, and a safety margin can be added to the final phase shift, such as adding an extra 2 seconds, to avoid the thermal circuit following up too early.

[0114] When the battery module discharge rate is switched from 0.5C to 1.5C, the left module experiences a deviation combination of decreased wind speed but rapid temperature rise due to obstructed heat dissipation path, while the right module only shows slight changes. After the server constructs a 2×2 target deviation matrix, it identifies the coupling in the left area as the dominant mode, thus obtaining a relaxation coefficient of 0.22.

[0115] The subsequent dynamic reorganization did not cause all the fans to increase their speed significantly. Instead, it prioritized increasing the power of the left duct, while only applying a moderate power reduction bias to the heat source side and maintaining a 15-second staggered start-up. As a result, the high-temperature zone inside the box was prioritized to be leveled out, and the thermal actuator avoided immediately entering a high-power reverse action.

[0116] The purpose of this mechanism is to introduce state-dependent elastic boundaries, instead of forcibly compressing all transient deviations with a single rigid matrix. Instead, it dynamically relaxes some errors based on the dominant direction and strength of the current coupling mode, thereby reducing high-frequency execution, suppressing compensation overshoot, and enhancing the control feasibility under complex loading conditions.

[0117] Furthermore, to ensure that the physical meaning of the target multidimensional control deviation matrix remains consistent across different sampling periods, the server can pre-fix the row and column mapping rules of the matrix; specifically, it can be agreed that: the row dimension corresponds to the spatial region or partition number, the column dimension corresponds to the variable category, and the column order in the entire text is maintained as wind speed deviation amplitude first and temperature deviation amplitude second; when the original deviation matrix is ​​organized in N×2 form, each row corresponds to different regions at the same time, and each column corresponds to two types of deviation variables in the same group of regions;

[0118] Regardless of whether the subsequent process involves direct matrix decomposition or eigenvalue decomposition of the relevant matrix constructed from the original deviation matrix, the object mapped by the target multidimensional control deviation matrix remains unchanged, thus avoiding the situation where the same matrix structure is given different physical interpretations at different times.

[0119] Furthermore, the relaxed error tolerance value and the elastic decoupling relaxation coefficient in the paper are a sequential mapping relationship rather than two independent new parameters; the former is the original result obtained by decomposition calculation, and the latter is the application name after extracting the original result and directly configuring it into the control calculation link; in this embodiment, the two values ​​are the same, only the links they are in are different.

[0120] Accordingly, the dynamic reconfiguration parameter refers only to the intermediate control result obtained by combining the current working state data, the elastic decoupling relaxation coefficient, and the pre-configured multivariable decoupling control matrix. Subsequently, it is mapped to the compensation gain amplitude on the fluid side and the compensation power bias on the thermodynamic side, respectively. Through the above fixed conventions, the matrix construction, eigenvalue decomposition, relaxation configuration, and instruction generation can be kept consistent in terms of terminology and data flow.

[0121] In a preferred embodiment of the present invention, the multivariable control server is further configured to: set a moving data calculation window for statistical data; synchronously monitor and statistically analyze the control command reversal rate data generated by the fluid actuator and the thermodynamic actuator due to compensation intervention within the moving data calculation window; and monitor and record the dead zone dwell time data of the thermodynamic actuator when it is in the dead zone state range.

[0122] The multivariate control server is also used to: generate an execution network dissipation index that characterizes the degree of mechanical fatigue accumulation of the actuator by multiplying the control command flip rate data with a first preset weight and summing the product of the inverse of the dead zone dwell time data and a second preset weight; and to obtain a preset equipment durability loss threshold.

[0123] In response to the network dissipation index being greater than or equal to a preset device durability loss threshold, the output compensation time-domain staggered phase shift is incremented to extend the action time interval; or, in response to the network dissipation index being less than the preset device durability loss threshold, the current output compensation time-domain staggered phase shift is maintained to preserve the action time interval.

[0124] This embodiment provides a mechanism for adaptively adjusting the peak phase shift based on the actuator's motion consumption. Specifically, after the aforementioned test chamber has been running continuously for dozens of hours, even if the field quantity control effect is still acceptable, the mechanical fatigue and performance degradation of the actuator may still occur due to the frequent speed increases and decreases of the fan and the repeated switching of the power level of the heater.

[0125] In other words, focusing solely on temperature and wind speed results is sometimes insufficient to reflect whether the equipment is being over-controlled. To address this issue, this embodiment further monitors the action characteristics of the execution network itself, in addition to the control results.

[0126] The server sets a moving data calculation window, for example, the last 120 seconds as a statistical window; within this window, it synchronously monitors the control command reversal rate data generated by the fluid actuator and thermodynamic actuator due to compensation intervention; the reversal rate can be understood as the frequency of command direction or gear switching per unit time.

[0127] For example, if within 120 seconds, the fan command undergoes 8 directional reversals between speed increase, speed decrease, speed increase, leveling off, and speed decrease, and the thermodynamic actuator undergoes 6 effective reversals between heating enhancement, heating reduction, cooling intervention, and cooling withdrawal, then the comprehensive reversal rate data within this window can be obtained.

[0128] At the same time, the server monitors the dead zone dwell time data of the thermodynamic actuator; the dead zone state here can be understood as: although the actuator receives a small adjustment command, it does not actually output an effective heat change due to its own physical characteristics, power resolution or protection strategy.

[0129] For example, if the minimum effective power adjustment step size of a heating module is 3%, then small corrections between 0% and 3% may be absorbed in the dead zone. If the system frequently allows the thermodynamic actuator to briefly enter and then quickly exit at the edge of the dead zone, it indicates that the compensation command repeatedly probes near this range but is difficult to form a stable and effective output, and there is obvious control dissipation.

[0130] Furthermore, in order to maintain consistency with the reciprocal of the subsequent dead zone dwell time data, the dead zone dwell time data in this embodiment is preferably understood as the representative continuous dwell time after a single entry into the dead zone within the moving window, such as the average continuous dwell time, the median continuous dwell time, or the most recent continuous dwell time, rather than the simple cumulative total time within the window.

[0131] The engineering implications are as follows: when the representative continuous dwell time is short, it indicates that the actuator is more likely to experience frequent small oscillations or state switching near the dead zone. Although the thermodynamic command reaches the dead zone multiple times, it is difficult to maintain static or maintain the current power level, which often corresponds to a higher ineffective regulation density.

[0132] When the representative continuous dwell time is relatively long, it may indicate that the system experiences fewer dead zone edge flips within the window, and the execution state is relatively stable. Therefore, the reciprocal of this data is used in the execution network dissipation index to reflect the logic that the state switching frequency is positively correlated with the execution network dissipation index.

[0133] Based on this, the server calculates the network dissipation index; it can be expressed in a simple engineering way: control instruction flip rate multiplied by the first preset weight, plus the reciprocal of dead zone dwell time multiplied by the second preset weight; during the calculation, both the control instruction flip rate and the reciprocal of dead zone dwell time need to be normalized and desensitized to ensure that the calculation result is a dimensionless dissipation index.

[0134] For the sake of intuitive deduction, let's assume the first preset weight is 0.7 and the second preset weight is 0.3. If the normalized tortuosity rate in the last 120 seconds is 0.8 and the dead zone dwell time is 15 seconds, then its reciprocal is approximately 0.067, resulting in a dissipation index of approximately 0.8 × 0.7 + 0.067 × 0.3 ≈ 0.58. If the preset equipment durability loss threshold is 0.55, then this index has already exceeded the threshold.

[0135] At this point, the server will increment the compensated time-domain phase shift of the current output, for example, from 15s to 18s. After the increase, the thermodynamic action follows more slowly, and the overlapping action between the actuators is reduced, thereby mitigating the mutual resistance. If the dissipation index is only 0.32, which is lower than the threshold, the existing phase shift will be maintained unchanged.

[0136] Furthermore, the incremental calculation does not need to be a sudden increase all at once; a step-by-step or proportional method can be used. For example, when the threshold is exceeded but the exceedance is less than 10%, the increment is 2 seconds each time; when the exceedance is greater than 30%, the increment is 5 seconds each time. This can balance life protection and control stability. Different durability loss thresholds can also be set for different equipment models. For example, high-power contact heaters can withstand a lower degree of frequent operation, so their threshold can be set lower; the threshold of continuously adjustable electronic expansion valves can be set appropriately higher.

[0137] As a redundancy protection strategy, if maintenance, manual intervention, or equipment self-testing occurs within the moving window, these actions should not be mistakenly included in the flip rate. Therefore, the server can shield this part of the data based on the maintenance flag or manual / automatic switching signal. If the dead zone dwell time is 0, it means that the thermodynamic actuator has not entered the dead zone. At this time, the reciprocal will be infinite and is not suitable for direct calculation.

[0138] To address this, a minimum replacement value can be set, such as limiting the lower limit of the dwell time to 1 second, or setting the contribution of this item to 0 when not entering the dead zone; if the phase shift has reached the allowable upper limit after increasing, for example, it has increased to 45 seconds, but the dissipation index continues to exceed the threshold, it indicates that the root cause may not be insufficient time domain peak shifting, but rather abnormal operating conditions or actuator aging. In this case, a maintenance alarm should be triggered instead of continuing to increase the delay without upper limit.

[0139] In the 31st hour of the 48-hour aging test, the battery module began to enter a cycle of alternating high and low rates, and the fluctuation of the internal operating conditions intensified.

[0140] Although the temperature deviation remains within the allowable range, the server found that the direction of the fan inverter command was reversed 10 times in the last 120 seconds, the effective power level of the thermodynamic execution end was switched 7 times, and the heating module briefly entered and exited near the low power dead zone multiple times. The calculated representative continuous dead zone dwell time is 12 seconds.

[0141] After calculation according to the preset weights, the network dissipation index exceeded the durability loss threshold. Therefore, the system increased the compensation time-domain phase shift from 15s to 20s. After the adjustment, the flip rate in the next statistical window decreased, the reciprocating attempts near the thermodynamic dead zone decreased, and the equipment operation became significantly smoother.

[0142] The purpose of this mechanism is to incorporate both control quality and execution life into the control closed loop, so that while meeting the field quantity adjustment requirements, the system actively avoids exchanging temporary stability for excessively frequent compensation, thereby improving the overall technical reliability and long-term operational stability of the machine.

[0143] Furthermore, to avoid ambiguity in the statistical definition of control command flip rate data, it can be uniformly understood as a comprehensive flip rate index composed of the number of flips of fluid execution terminals and the number of flips of thermodynamic execution terminals within the moving data calculation window;

[0144] In practice, the effective number of flips of the two types of terminals within the window can be counted separately, and then converted into their respective flip rates according to a unified time base. The control command flip rate data can be obtained by any of the preset methods of summation, weighted summation or normalization merging. Once the device is deployed and one of the merging methods is selected, it remains unchanged within the same system operation cycle to ensure the comparability of the network dissipation index before and after execution.

[0145] Furthermore, the output compensation time-domain staggered phase shift is incrementally calculated, which can be preferably understood as follows: the basic calibration phase shift obtained based on the absolute value of the time difference between the thermal capacity response hysteresis time and the flow field pressure build-up time is used as the starting point, and an incremental correction value for durability protection is superimposed on this basis to form the current output compensation time-domain staggered phase shift.

[0146] In other words, the incremental operation does not change the physical source of the basic calibrated phase shift, but rather adds a relaxation to the basic value; when the network dissipation index falls below the threshold, the current output value can be maintained, or it can be gradually rolled back to the basic calibrated phase shift when the preset recovery conditions are met in the future; through such an agreement, the source, adjustment method and output object of the compensation time-domain staggered phase shift can be kept consistent in the technical solution;

[0147] In a preferred embodiment of the present invention, the environmental data acquisition terminal includes: a wind speed sensing module and a temperature sensing distribution node group; wherein, the wind speed sensing module is used to collect the internal wind pressure distribution of the physical space inside the preset box as a component of the circulating airflow velocity data; the temperature sensing distribution node group is used to collect the internal space temperature gradient of the physical space inside the preset box as a component of the flow field temperature data.

[0148] This embodiment provides a mechanism for arranging environmental data acquisition terminals. Specifically, in the battery module aging test chamber mentioned above, if only a single temperature probe and a single wind speed measuring point are set up, the server can obtain the conclusion that the overall temperature inside the chamber is too high or the overall wind is too weak, but it is difficult to identify spatial coupling problems such as local flow obstruction and heat island shift. Therefore, this embodiment adopts a combination of wind speed sensing module and temperature sensing distribution node group to obtain input data that can better characterize the actual flow and heat field inside the chamber.

[0149] The wind speed sensing module can be placed at the inlet of the circulating air duct, the return air outlet, and the key flow guide section inside the box to collect the internal wind pressure distribution, which constitutes part of the circulating airflow velocity data.

[0150] The wind pressure distribution here does not necessarily have to be output in the form of absolute pressure. It can also be expressed by multi-point differential pressure, wind speed conversion value or equivalent flow resistance index; the temperature sensor distribution node group can be arranged along different spatial positions on the left, middle, right and upper, middle and lower of the box to collect the internal space temperature gradient; in this way, the server receives no longer a single point temperature, but a set of node data that can reflect the direction of spatial temperature difference.

[0151] To perform microscopic simulations, we can assume that there are 3 wind pressure measurement points P1, P2, and P3 and 6 temperature nodes T1 to T6 inside the chamber. At a certain moment, the corresponding converted wind velocities of P1, P2, and P3 are 2.6 m / s, 1.7 m / s, and 2.4 m / s, respectively, which reflects that the airflow in the middle duct is significantly weak. The temperatures of T1 to T6 are 45.2℃, 45.0℃, 46.3℃, 45.8℃, 44.9℃, and 45.1℃, respectively, which reflects that there is heat accumulation in the upper and middle parts.

[0152] The server constructs spatial distribution characteristics based on this, rather than using only a simple average value; in this way, when the central guide vane causes local wind resistance to increase due to tooling offset, the system is more likely to identify this as a spatial coupling disturbance, rather than a random disturbance signal of the overall operating conditions.

[0153] As a redundancy protection strategy, if some temperature nodes fail, the temperature gradient can be calculated again after interpolating adjacent nodes, replacing them with the mean value of the same layer, or directly removing the failed points. However, the confidence level of the judgment in this cycle should be reduced.

[0154] If a wind speed sensor module drifts under high temperature and high humidity conditions, it can be corrected by comparing with the fan command and historical steady-state flow curve; if the correction fails, the measuring point is marked as unavailable and the control is temporarily maintained by other measuring points.

[0155] During the 12-hour test in the same test chamber, the heat sink of the battery module near the upper right corner became blocked, causing the local temperature node in the upper right corner to rise rapidly from 45.1℃ to 46.5℃, while the wind pressure measurement point in the corresponding return air area showed that the converted wind speed dropped to 1.6m / s; due to the use of distributed temperature node group and multi-point wind pressure acquisition, the server was able to clearly locate the abnormal flow-heat coupling in the upper right corner and trigger more targeted compensation accordingly, rather than mistakenly assuming that the entire chamber needed to increase the total air volume or reduce the heat load across the board;

[0156] The purpose of this mechanism is to improve the ability to perceive the non-uniformity of the space inside the box, so that the control input includes not only the overall level, but also the local gradient and distribution characteristics, thereby supporting the subsequent disturbance identification, matrix construction and feedforward compensation calculation.

[0157] In a preferred embodiment of the present invention, the fluid actuator includes a duct power component with a variable frequency drive; the thermodynamic actuator includes a heat source and cold source conversion component with a power adjustment interface; wherein, the duct power component is used to convert the received fluid feedforward compensation command into a change in air pressure; the heat source and cold source conversion component is used to convert the received heat source feedforward compensation command into a heating or cooling power adjustment through electrothermal conversion behavior.

[0158] This embodiment provides an implementation mechanism for an execution terminal. Specifically, in the above-mentioned test chamber scenario, if the execution terminal can only perform on / off control, such as the fan can only be fully or half-open, and the heat source can only be started and stopped, then even if the decoupling logic of the front end is designed in a more detailed manner, it will be difficult to implement smoothly in the end. Therefore, this embodiment adopts a duct power component with a variable frequency drive and a heat source and cold source conversion component with a power adjustment interface.

[0159] The duct power components may include centrifugal fans, axial fans, flow dampers, and variable frequency drives; the fluid feedforward compensation command sent by the server may be a gain amplitude, a target speed offset, or a target air pressure offset; after receiving the command, the variable frequency drive converts it into motor frequency adjustment to change the fan output air pressure;

[0160] For example, when the server issues a +8% wind pressure compensation command, the driver can increase the fan frequency from 38Hz to 41Hz, which corresponds to increasing the static pressure in the main air duct from 210Pa to 228Pa. Since the internal circulation structure is fixed, this change in wind pressure is further converted into an improvement in the flow field velocity distribution.

[0161] Thermodynamic execution terminals may include heaters, evaporators, compressor control interfaces, electronic expansion valves, or heating / cooling switching modules; the heat source feedforward compensation commands sent by the server may be manifested as heating power bias, cooling capacity bias, or heating / cooling switching direction;

[0162] For example, when in heating maintenance mode, if the server provides a -6% thermal power bias, the heat source and cold source conversion components can reduce the electric heating output from 5kW to 4.7kW; when in cooling maintenance mode, if a +4% cooling capacity bias is provided, the opening of the electronic expansion valve and the compressor load will increase accordingly, resulting in an increase in cooling power.

[0163] Here, the electrothermal conversion behavior is manifested as the adjustment of heating or cooling power. In engineering implementation, this can be understood as follows: the thermodynamic execution terminal receives electrical signals or digital power adjustment commands, while the result on the thermal environment inside the box is manifested as equivalent heat input or equivalent heat extraction.

[0164] For electric heaters, the process can be directly reflected as the conversion of electrical energy into thermal energy; for cold source links such as compressor refrigeration and evaporative heat exchange, it is reflected as the change in cooling capacity triggered by the electric drive control quantity, that is, from the perspective of heat balance in the chamber, it is manifested as negative heat power regulation; thus, both heating and cooling processes can be uniformly abstracted as the adjustable control of the net heat exchange in the chamber from the thermodynamic side, rather than limiting all cold sources to adopt a single direct resistance heating mechanism.

[0165] When working in conjunction with the aforementioned peak-shifting logic, the duct power components typically execute first, while the thermodynamic side operates only after the phase shift has occurred. In this way, the fluid feedforward compensation and heat source feedforward compensation generated at the front end can be implemented separately in different physical execution links, avoiding a single actuator from bearing all the coupled regulation tasks.

[0166] As a redundancy protection strategy, if the fan is already close to the maximum allowable frequency, for example, if the server requests a further increase of 10%, but the drive detects that the safety limit has been reached, the instruction should be truncated to the upper limit value and the fluid side saturation status should be sent back to the server so that the thermal side compensation weight can be appropriately increased in the future.

[0167] If the heat source and cold source conversion components are under anti-freeze protection, overheat protection, or compressor minimum downtime limit, then even if a heat source feedforward compensation command is received, execution should be delayed or reduced, and the actual executable capability should be fed back to the server; after receiving the execution limitation information, the server can readjust the dynamic reorganization parameters for the next cycle.

[0168] During the 26th hour of aging test, the system detected the simultaneous occurrence of the collapse of the central wind field and the upper heat island. The server first outputs a fluid feedforward compensation of +3Hz fan frequency, and the duct power component establishes a higher wind pressure within 3 seconds. After 15 seconds, the thermodynamic execution terminal executes heat source feedforward compensation of -0.4kW heating power, so that the process of temperature tending to steady state has higher monotonicity and stability.

[0169] If the fan is already running near the 45Hz upper limit, the driver is only allowed to increase it to 46Hz and send the saturation state back. In the next window, the server will reduce the number of additional commands to the fan and instead let the thermodynamic side handle more slow variable adjustments.

[0170] The purpose of this mechanism is to give the upper-level decoupled control logic a clear physical landing point, and to map the compensation instructions into executable wind pressure changes and heat power adjustments, thereby ensuring that the algorithm output can be realized by the equipment in a real, continuous and constrained manner.

[0171] In a preferred embodiment of the present invention, the multivariable decoupling control system further includes a front-end monitoring and interaction terminal; the front-end monitoring and interaction terminal is used to: receive the state fluctuation frequency band characteristics and the compensation time-domain peak shift amount forwarded by the multivariable control server; and to visualize and display the received state fluctuation frequency band characteristics and the compensation time-domain peak shift amount and to provide alarm threshold over-limit prompts.

[0172] This embodiment provides a front-end monitoring and interaction mechanism; specifically, during the long-term operation of the aforementioned test chamber, if the operator can only obtain two apparent values, namely the current temperature and the current fan frequency, it is impossible to trace the internal logic of the system delaying the action of the heat source during a specific period, and it is also difficult to detect in time whether the abnormal disturbance frequency bands recur.

[0173] Therefore, this embodiment adds a front-end monitoring and interactive terminal in addition to the control server to display the frequency band characteristics of state fluctuations and the compensation time-domain peak shift amount;

[0174] The front-end monitoring and interaction terminal can be an industrial control computer interface, a touch screen, a host computer page, or a remote operation and maintenance terminal; after the server forwards the identified status fluctuation frequency band characteristics to the front end, it can draw a disturbance frequency band intensity change diagram along the time axis;

[0175] For example, the horizontal axis represents time, the vertical axis represents the normalized perturbation frequency or band energy, and the color intensity indicates the coupling strength; at the same time, the compensation time-domain peak shift can also be displayed as a curve that changes with time, making it easy to observe when the system uses a larger wind and heat peak shift.

[0176] For the sake of simple deduction, assume that in a certain hour, the front-end interface refreshes its status once per minute, with the high-frequency disturbance energy increasing significantly from the 15th to the 18th minute, and the phase shift gradually increasing from 15s to 22s.

[0177] Operators can easily see from the interface that this is not simply a temperature increase, but rather that the system has proactively increased the off-peak time after detecting the deterioration of the frequency band characteristics. If the execution network dissipation index is also displayed, it is even easier to determine that the adjustment is to control actuator wear rather than a malfunction.

[0178] Alarm threshold exceeding prompts can also be configured together; for example, when the frequency characteristics of the status fluctuation band are higher than the warning threshold for three consecutive windows, it indicates that there is a continuous coupling disturbance in the box; when the compensation time domain peak shift exceeds 80% of the set upper limit, it indicates that the execution protection is tightening and suggests checking the air duct or the loading status of the device under test; such prompts help maintenance personnel to troubleshoot problems from both process and equipment levels.

[0179] As a redundancy protection strategy, if the communication between the front end and the server is interrupted, it should not affect the operation of the underlying control. At this time, the server continues to perform decoupling control locally, only caching the unsuccessfully sent visualization data locally, and retransmitting the summary data after the link is restored.

[0180] If the frequency band feature data received by the front end is incomplete, only the most recent valid point can be displayed and the data delay can be marked to prevent operators from making misjudgments; if the user sets the alarm threshold too low, resulting in frequent pop-ups, the output of repeated signals can be limited by the graded threshold and the shortest alarm interval.

[0181] During the 40-hour aging test night shift, the maintenance personnel observed through the remote terminal that the intensity of the disturbance frequency band in the right panel was continuously increasing, and the compensation time domain phase shift increased from 18s to 25s. The system issued a prompt indicating continuous coupling disturbance and asked to check the right-side guide channel. Based on this, the maintenance personnel arranged a shutdown window inspection and found that the right-side fixture position was offset, thus eliminating subsequent risks in a timely manner.

[0182] The purpose of this mechanism is to make the judgment criteria and peak-shaving strategies within the server transparent, so that operators can understand the disturbance characteristics behind the control actions and intervene in maintenance in a timely manner when limits are exceeded, thereby improving the monitorability of system parameters and the traceability of equipment operating status.

[0183] In a preferred embodiment of the present invention, the number of environmental data acquisition terminals, fluid execution terminals, and thermodynamic execution terminals is set to at least one.

[0184] This embodiment provides a mechanism for expanding the number of terminals; specifically, in the aforementioned battery module aging test chamber scenario, there are significant differences in the volume of different chambers, air duct structures, and tooling layouts.

[0185] If the system is limited to a single sensing terminal, a single fluid terminal, and a single thermal terminal, its applicability is narrow and it is not conducive to implementation in multi-duct, multi-heat source, or zoned temperature control equipment. Therefore, in this embodiment, the number of environmental data acquisition terminals, fluid execution terminals, and thermodynamic execution terminals is set to at least one to adapt to test equipment of different scales.

[0186] In its simplest form, one environmental data acquisition terminal, one fluid actuator terminal, and one thermodynamic actuator terminal can be used for centralized control of a small-volume test chamber.

[0187] In the extended form, multiple environmental data acquisition terminals can be used for partitioned sampling, multiple fluid actuators can act on the left and right air ducts or the upper and lower circulation branches respectively, and multiple thermodynamic actuators can correspond to the main heating zone, auxiliary heating zone and independent refrigeration circuit respectively; the server can treat these terminals as different control objects and coordinate them in a unified manner.

[0188] Here's a simplified analogy: If the equipment is upgraded to a dual-duct structure, fluid actuators F1 and F2 can be set up to control the left and right ducts respectively; temperature sampling is divided into upper-level node groups and lower-level node groups; thermodynamic actuator H1 is responsible for the main heating, and H2 is responsible for the cooling branch.

[0189] During a certain operation, if the server detects that the temperature rises too quickly in the upper right area and the wind speed drops in the right air duct, it can issue a larger wind pressure compensation only to F2 and a moderate cooling bias to H2, without having to activate F1 and H1 at the same time; in this way, at least one configuration of the system is naturally compatible with the expansion from a single zone to multiple zones.

[0190] As a redundancy protection strategy, if one of the multiple similar terminals fails, such as the right duct execution terminal going offline, the server can switch to degrade mode: on the one hand, it uses the left duct terminal for partial compensation, and on the other hand, it increases the thermal side peak shifting delay and reduces aggressive control of the failed zone.

[0191] At the same time, an alarm is reported to the front-end monitoring terminal; if the sampling results of multiple environmental data acquisition terminals are contradictory, they can be filtered by timestamp verification, physical adjacency comparison or majority consistency principle to avoid individual abnormal nodes misleading the overall control.

[0192] During the mass production verification phase, the same control architecture was deployed in a large test chamber with a volume of 4 cubic meters. The equipment has two sets of air duct power components, two sets of heating units and one set of centralized cooling unit, and 12 temperature nodes and 4 wind pressure measurement points are arranged inside the chamber.

[0193] After the server recognizes the increased load in the lower left area based on multi-terminal input, it only makes targeted adjustments to the left air duct and the main heating unit, while keeping the right branch basically stable. It can be seen that this structure can be used for small single-zone equipment and can also be smoothly extended to large-zone equipment.

[0194] The purpose of this mechanism is to provide a unified implementation framework for enclosure systems of different sizes and topologies, so that the control architecture does not depend on a fixed number of sensing and execution units, and can dynamically expand or reduce the logical links between single-terminal and multi-terminal scenarios, thereby enhancing versatility.

[0195] The foregoing has provided a detailed description of one embodiment of the present invention, but this description is merely a preferred embodiment and should not be construed as limiting the scope of the invention. All equivalent variations and modifications made within the scope of the claims of this invention should still fall within the patent coverage of this invention.

Claims

1. A decoupled control system for multivariable circulating airflow velocity and temperature within an incubator, characterized in that, include: Environmental data acquisition terminal, multivariable control server, fluid execution terminal, and thermodynamic execution terminal; The environmental data acquisition terminal is used to acquire the current working status data of the physical space inside the preset box, and send the current working status data to the multivariable control server. The current working status data includes circulating airflow velocity data and flow field temperature data. The multivariable control server is used to extract transient dynamic features characterizing the rate of change of the circulating airflow velocity data and flow field temperature data over time based on the current operating state data. When the transient disturbance frequency calculated based on the current operating state data is greater than or equal to a preset disturbance frequency band separation threshold, thus detecting a cross-coupling disturbance trigger, the server sends a fluid feedforward compensation command to the fluid execution terminal and a heat source feedforward compensation command to the thermodynamic execution terminal. The transient dynamic features refer to the rate of change vector extracted by performing a first-order difference operation on the sampled sequence, and the acceleration features obtained by calculating the second derivative. The multivariable control server is used to calculate the transient disturbance frequency and detect cross-coupling disturbance triggers in the following ways: The reference state data of thermodynamics and fluidity are obtained from the preset storage space of the multivariable control server; The reference state data is compared with the current working state data, and the difference between the circulating airflow velocity data and the flow field temperature data and the reference data is calculated to generate state fluctuation frequency band characteristics that characterize the changes in wind speed deviation amplitude and temperature deviation amplitude over time. The frequency band characteristics of the state fluctuation are transformed in the time and frequency domains to calculate the transient disturbance frequency of the current input fluctuation. In response to the transient disturbance frequency being greater than or equal to a preset disturbance frequency band separation threshold, the preset disturbance frequency band separation threshold is used as the reference threshold for the current system determination, identification information is written to the system instruction register, and it is determined that a cross-coupling disturbance trigger has been detected. Alternatively, in response to the transient disturbance frequency being less than the preset disturbance band separation threshold, the identification information of the system instruction register is cleared, and it is determined that no cross-coupling disturbance trigger has been detected. In addition, the preset thermal capacity response hysteresis time and the preset flow field pressure build-up time are obtained from the physical response inertial database embedded in the multivariable control server, and the absolute value of the time difference between the two is output to the thermodynamic execution terminal as the compensation time domain staggered phase shift amount. The fluid execution terminal is used to receive the fluid feedforward compensation command and perform fluid wind pressure regulation response; The thermodynamic execution terminal is used to receive the heat source feedforward compensation command and, based on the compensation time-domain staggered phase shift amount, insert a delayed start-up time difference to execute the thermal load adjustment response.

2. The decoupled control system for multivariable circulating airflow velocity and temperature in the incubator according to claim 1, characterized in that, The multivariate control server is also used for: If it is determined that a cross-coupling disturbance has been detected, a target multidimensional control deviation matrix is ​​determined, which is mapped by the current working state data and consists of the wind speed deviation amplitude and the temperature deviation amplitude. The row dimension of the target multidimensional control deviation matrix corresponds to different regions of the preset physical space inside the box, and the column dimension corresponds to the wind speed deviation amplitude and the temperature deviation amplitude. The target multidimensional control deviation matrix is ​​deconstructed by matrix eigenvalue decomposition to calculate the relaxed error tolerance value used to reduce the actuator action reversal frequency. Extract the relaxed error tolerance value and directly configure the extracted relaxed error tolerance value as the elastic decoupling relaxation coefficient.

3. The decoupled control system for multivariable circulating airflow velocity and temperature in the incubator according to claim 2, characterized in that, The multivariate control server is also used for: Combining the current working state data and the elastic decoupling relaxation coefficient, the elastic decoupling relaxation coefficient is used as a state relaxation boundary condition and substituted into the multivariable decoupling control matrix pre-configured by the multivariable control server for matrix multiplication to generate dynamic recombination parameters; Based on the dynamic recombination parameters, compensation gain amplitudes adapted to the fluid execution terminal are generated as the fluid feedforward compensation commands. Based on the dynamic recombination parameters, compensation power biases adapted to the thermodynamic execution terminal are generated as the heat source feedforward compensation commands. Specifically, the compensation time-domain peak shift amount output by the multivariable control server to the thermodynamic execution terminal is obtained by acquiring the preset thermal capacity response hysteresis time and the preset flow field pressure build-up time recorded in the physical response inertial database embedded in the multivariable control server, and calibrating the absolute value of the time difference between the two.

4. The decoupled control system for multivariable circulating airflow velocity and temperature in the incubator according to claim 1, characterized in that, The multivariate control server is also used for: Set up the mobile data calculation window used for statistical data; Within the mobile data calculation window, the control command reversal rate data generated by the fluid actuator and the thermodynamic actuator due to compensation intervention are simultaneously monitored and statistically analyzed. Monitor and record the dead zone dwell time data of the thermodynamic execution terminal when it is in the dead zone state range.

5. The decoupled control system for multivariable circulating airflow velocity and temperature in the incubator according to claim 4, characterized in that, The multivariate control server is also used for: By multiplying the control command flip rate data with a first preset weight and summing the product of the inverse of the dead zone dwell time data and a second preset weight, an execution network dissipation index characterizing the degree of mechanical fatigue accumulation of the actuator is generated. Obtain the preset device durability loss threshold; In response to the network dissipation index being greater than or equal to the preset device durability loss threshold, the output compensation time-domain staggered phase shift is incremented to expand the action time interval. Alternatively, in response to the execution network dissipation index being less than the preset device durability loss threshold, the currently output compensation time-domain phase shift is maintained to preserve the action time interval.

6. The decoupled control system for multivariable circulating airflow velocity and temperature in the incubator according to any one of claims 1 to 5, characterized in that, The environmental data acquisition terminal includes: a wind speed sensing module and a temperature sensing distribution node group; The wind speed sensing module is used to collect the internal wind pressure distribution of the physical space inside the preset box as a component of the circulating airflow speed data; The temperature sensing distribution node group is used to collect the internal spatial temperature gradient of the physical space inside the preset box as a component of the flow field temperature data.

7. The decoupled control system for multivariable circulating airflow velocity and temperature in the incubator according to any one of claims 1 to 5, characterized in that, The fluid actuator includes a duct power assembly with a variable frequency drive; the thermodynamic actuator includes a heat source and cold source conversion assembly with a power adjustment interface. The duct power assembly is used to convert the received fluid feedforward compensation command into a change in wind pressure. The heat source and cold source conversion component is used to express the received heat source feedforward compensation command as a heating or cooling power adjustment amount through electrothermal conversion behavior.

8. The decoupled control system for multivariable circulating airflow velocity and temperature in the incubator according to any one of claims 2 to 5, characterized in that, The multivariable decoupling control system further includes a front-end monitoring and interaction terminal; the front-end monitoring and interaction terminal is used for: Receive the state fluctuation frequency band characteristics and the compensation time-domain peak shift amount forwarded by the multivariable control server; The received state fluctuation frequency band characteristics and the compensated time-domain peak shift are visualized and the alarm threshold is exceeded.

9. The decoupled control system for multivariable circulating airflow velocity and temperature in the incubator according to any one of claims 1 to 5, characterized in that, The number of the environmental data acquisition terminal, the fluid execution terminal, and the thermodynamic execution terminal is set to at least one.

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