An aero-engine whole machine test bench electric control system and method

Abstract

The application discloses an aero-engine whole machine test bench electric control system and method, and belongs to the technical field of aero-engine test and measurement. In view of the problems of the existing test bench electric control system, such as model speciality, poor expansibility, low model changing efficiency, a general and modular solution is provided. The system is compatible with different types of control cabinets in design, integrates PLC which can be flexibly configured, relays and adapter plugs which are divided according to functions, and realizes the reuse of hardware resources. The matched modular software supports the 'one-key switching' of different types of engine control programs and operation interfaces. At the same time, the test bench control cable is model special and the interface is standardized, the quick model changing is realized through the plug connection, and the complex internal rewiring is avoided. The application significantly improves the adaptability of the test bench to different types of engines, saves the equipment space and development cost, shortens the test preparation period, and effectively improves the test efficiency and safety.

Description

Technical Field

[0001] This application belongs to the field of electrical control system design for aero-engine test benches, and specifically relates to an electrical control system and method for aero-engine test benches. Background Technology

[0002] Most existing domestic solutions for the electrical control systems of aero-engine test benches utilize programmable logic controllers (PLCs) as the hardware foundation, employing a distributed I / O control approach. Different engine models use independent control cabinets and PLC control systems, with the PLC control system for one engine model serving as the master control station for the test bench's electrical control system. The PLC control systems for other engine models communicate with the master control station via a Profibus-DP bus. Adding a new engine model requires expanding the control substation, adding a control cabinet and a new PLC control system to achieve independent control of different engine models. The above technical solutions suffer from the following drawbacks:

[0003] The test bench electrical control system can only be matched with specific engine models. When conducting whole-engine tests on different engine models, a new test bench electrical control system needs to be designed, which involves the procurement of control cabinets and PLC systems, the customization and solidification of programs and their deployment. This requires high economic costs and a long time cycle, resulting in a long development cycle for aero-engines.

[0004] As the number of engine models increases, the limited space layout of the test bench may mean that a single test bench can only be used for a fixed number of engine models. If new engine models are added later, the control cabinets and PLC control systems of the existing models must be removed, which presents significant technical limitations.

[0005] Testing new engine models requires extensive wiring and control cable connection work within the control cabinet. This process is time-consuming and prone to errors and omissions, impacting testing efficiency, equipment safety, and overall test safety. Summary of the Invention

[0006] To address the aforementioned problems, this application provides an electrical control system for an aero-engine test bench, used to simulate the engine's installed state on the test bench and complete test control and monitoring, including:

[0007] Throttle console, PLC control system, control cabinet, control cable for the test bench, host computer and data acquisition system;

[0008] The throttle console is connected to the engine's onboard electronic controller via the console control cable, and is used to provide throttle lever angle signals;

[0009] The control cabinet integrates the PLC control system, relay group, multiple function-defined adapter plugs, and measurement module.

[0010] The PLC control system connects to the engine electronic controller by driving the relay group and via the adapter plug and the bench control cable, for inputting engine control commands and collecting status parameters.

[0011] The host computer is communicatively connected to the PLC control system and includes STEP7 configuration software for PLC hardware configuration and program writing, and WinCC configuration software for operation command input and status parameter monitoring.

[0012] The data acquisition system is communicatively connected to the host computer and the PLC control system, and is used to collect the engine's control parameters and status parameters.

[0013] Preferably, the relays and adapters in the control cabinet are divided and defined according to the control functions, so that a set of PLC control system and relay group can be compatible with the control functions of different engine models by modifying the hardware address configuration; when a new engine model is added, the control cabinet and its internal PLC control system and relays can be directly reused.

[0014] Preferably, the adapter plug includes at least:

[0015] The first adapter plug is used to transmit the power supplied by the relay driven by the PLC control system to the engine electronic controller. The voltage and current of the power supply are collected by the measurement module and fed back to the PLC control system.

[0016] The second and fourth adapter plugs are used to transmit bench control commands provided by the relays driven by the PLC control system to the engine electronic controller.

[0017] The third and fourth adapter plugs are used to transmit the digital status parameters output by the engine to the PLC control system via relay contacts.

[0018] The fifth adapter is used to connect the analog status parameters output by the engine to the PLC control system or a dedicated testing device.

[0019] The sixth adapter plug is used to connect the communication signals of the engine electronic controller to the test bench local area network.

[0020] Preferably, the bench control cable is used to connect the control cabinet and the engine electronic controller; different engine models are equipped with independently designed bench control cables, and each cable end is provided with a plug corresponding to the function definition of the adapter plug in the control cabinet; when changing the engine model, the corresponding model of bench control cable plug is connected to the adapter plug in the control cabinet, without the need to rewire inside the control cabinet.

[0021] Preferably, the STEP7 software in the host computer is designed with a modular approach to control programs, arranging the control programs for different engine models in independent functional modules, and enabling quick switching between engine models by calling the corresponding modules with a single click; the WinCC software provides separate configuration and control interfaces for different engine models, and enables quick switching between control interfaces for different engine models by calling the corresponding interface with a single click through the engine model selection button.

[0022] An electrical control method for an aero-engine test bench, employing the aforementioned electrical control system, includes the following steps:

[0023] Engine control signals are generated via the throttle console;

[0024] The PLC control system drives the relay group in the control cabinet according to the control logic, and transmits the control commands to the engine electronic controller via the adapter plug and the bench control cable.

[0025] The engine output status parameters are collected and fed back to the PLC control system through the adapter plug and bench control cable.

[0026] The host computer receives the operator's control input and sends it to the PLC control system, while also receiving and displaying engine status parameters from the PLC control system.

[0027] The data acquisition system collects and records engine parameters during the test run.

[0028] Technical problems to be solved:

[0029] 1) In existing technologies, the electrical control system of the test bench can only be matched with specific engine models. For the testing of new engine models, a new electrical control system needs to be designed and corresponding components need to be purchased, resulting in long development costs and time. This invention designs a control cabinet solution that is compatible with the control functions of different engine models. For new engine models, the control cabinet and its internal PLC, relays and other components can be directly reused, saving test bench space and reducing model development costs and time.

[0030] 2) In existing technologies, testing new engine models requires customizing, solidifying, and deploying control programs, resulting in long development cycles. This invention, based on a modular design principle, places the control programs and user interfaces for different engine models within independent functional modules. A one-click engine selection enables rapid switching between models, shortening the development cycle and improving testing efficiency.

[0031] 3) In existing technologies, testing new engine models requires rewiring and rewiring of control cables, resulting in lengthy preparation time and a high risk of incorrect or missing connections, impacting testing efficiency, equipment safety, and overall test safety. This invention designs a new control cable interface logic and form. Based on the functional definitions of relays and adapter plugs within the control cabinet, the engine interface is designed as a corresponding plug on the bench control cable end. Changing engine models simply requires connecting the different model bench control cable plugs to the adapter plugs in the control cabinet, achieving rapid and efficient model conversion and improving testing efficiency, equipment safety, and overall test safety. Attached Figure Description

[0032] Figure 1 This is a diagram showing the architecture of the electrical control system of the aero-engine test bench;

[0033] Figure 2 This is a diagram showing the internal connection logic of the control cabinet;

[0034] Figure 3 This is the first part of the diagram showing the internal connection logic and functional division of the control cabinet;

[0035] Figure 4 This is the second part of the diagram showing the internal connection logic and functional division of the control cabinet.

[0036] Figure 5 This is a flowchart of the software workflow in the host computer for bench control. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions in the embodiments of this application will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The described embodiments are only some, not all, of the embodiments of this application. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application. The embodiments of this application will be described in detail below with reference to the accompanying drawings.

[0038] The electrical control system of this aero-engine test bench consists of a throttle platform, a PLC control system, a control cabinet, test bench control cables, a host computer, and a data acquisition system. Its architecture is as follows: Figure 1 As shown, the test bench electrical control system is used to simulate the engine's installed state on the test bench, and to complete functions such as control input, measurement signal input and output, status monitoring, alarm display, and data transmission for various functional states during engine testing.

[0039] 1) The throttle console is connected to the engine's onboard electronic controller via a control cable, providing the electronic controller with throttle lever angle signals to control the engine's fuel supply pattern.

[0040] 2) The PLC control system is built on the hardware basis of S7-300 series PLC and integrated in the control cabinet. It is connected to the engine electronic controller through relays, adapter plugs and bench control cables. It is used for the input of engine control commands and the acquisition and measurement of status parameters. The PLC control system is connected to the test bench LAN through a network interface to realize data interaction with the bench control host computer, and can also realize data interaction with the data acquisition system, the electronic controller host computer and the process equipment control system.

[0041] 3) The control cabinet integrates a PLC control system, relays, adapters, measurement modules, and connecting lines. The relays and adapters are functionally divided and defined according to different control principles. Leveraging the flexible configuration of the PLC control system's hardware addresses, a single PLC control system and relays can be compatible with the control functions of different engine models. This facilitates the design and switching of electrical control systems for different engine test benches. Its internal connection logic and functional division design are as follows: Figures 2-4 As shown:

[0042] The engine electronic controller (ECU) is powered by relays driven by the PLC control system. Power is supplied to the ECU via the XS1 adapter, and the voltage and current are monitored in real-time by a measurement module connected to the PLC control system. Control commands are transmitted from the PLC control system to the ECU via the XS2 and XS4 adapters, serving as inputs for the ECU's logic. Digital status parameters output by the engine are transmitted to relays via the XS3 and XS4 adapters, with the relay contacts connecting to the PLC control system for acquisition. Analog status parameters output by the engine are transmitted to the PLC control system or dedicated testing equipment via the XS5 adapter. Communication signals from the ECU are connected to the test bench's local area network via the XS6 adapter, enabling data exchange with the ECU's host computer. This solution allows a single control cabinet to be used for different engine models. For new engine models, the control cabinet and its internal PLCs, relays, and other components can be reused, saving test bench space, model development costs, and time.

[0043] 4) The bench control cable is used to connect the bench to the engine electronic controller, providing a transmission medium for the engine's control inputs and status outputs. Different engine models have significantly different control cables, requiring independent design. Based on the functional definitions of the relays and adapters in the control cabinet, the engine's power supply, input / output, and communication interfaces are designed as corresponding plugs on the bench control cable. Changing engine models eliminates the need for wiring and cabling within the control cabinet; only the different models of bench control cables need to be connected to the adapters in the control cabinet. This significantly reduces pre-test preparation time, avoids incorrect or missing connections, improves testing efficiency, and enhances equipment and test safety.

[0044] 5) The host computer includes a bench-controlled host computer and an electronic controller host computer.

[0045] The test bench control host computer and the PLC control system are connected via the test bench's local area network for data exchange. The test bench control host computer integrates STEP7 and WinCC configuration software. STEP7 software is used for PLC control system hardware configuration, control program writing, and control logic implementation. The control program is designed with a modular approach, with control programs for different engine models located in different functional modules. A one-button operation is used to call the corresponding functional module, enabling rapid switching between different models. WinCC software is used for operator input of engine control commands and display and monitoring of engine output status parameters. Different engine models have separate configured operation control interfaces. A model selection button is used to call the corresponding engine model's operation control interface with one click, enabling rapid switching between different models. This significantly reduces preparation time before engine model conversion tests and improves testing efficiency. The software workflow in the test bench control host computer is as follows: Figure 5 As shown.

[0046] The communication interface between the electronic controller's host computer and the electronic controller is connected via the test bench's local area network. It can download control parameters and control laws to the electronic controller and read the engine accessory status parameters collected by the electronic controller. The host computer of the electronic controller is connected to the test bench control host computer and the data acquisition system via the test bench's local area network, enabling the interaction and synchronization of control data and measurement data between them.

[0047] 6) The data acquisition system is connected to the test bench control host computer and the electronic controller host computer through the test bench LAN to exchange data and can collect engine control parameters and their status parameters.

[0048] 1) This invention designs a control cabinet solution that enables a single control cabinet to be compatible with the control functions of different engine models. When a new engine model is added, the control cabinet and its internal PLC, relays and other components can be directly reused. Compared with the current technical solutions, this saves test bench space, model development costs and time.

[0049] 2) This invention adopts a modular design principle, arranging the control programs and operation interfaces of different engine models in independent functional modules. It enables quick switching between different models through one-click engine selection, which shortens the program development cycle and improves testing efficiency compared to current technical solutions.

[0050] 3) This invention designs a new control cable interface logic and form. Based on the functional definition of the relays and adapter plugs in the control cabinet, the power supply, input / output, and communication interfaces of the engine are designed as corresponding plugs on the bench control cable end. When changing the engine model, there is no need to perform control cable wiring and patching work in the control cabinet. It is only necessary to connect the different models of bench control cable plugs to the adapter plugs in the control cabinet. Compared with the current technical solutions, this greatly reduces the preparation time before the test, avoids the problems of incorrect connection and omission, and improves the test efficiency, equipment safety, and test safety.

[0051] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. An electrical control system for an aero-engine test stand, used to simulate the engine's installed state on the test stand and complete test control and monitoring, characterized in that, include: Throttle console, PLC control system, control cabinet, control cable for the test bench, host computer and data acquisition system; The throttle console is connected to the engine's onboard electronic controller via the console control cable, and is used to provide throttle lever angle signals; The control cabinet integrates the PLC control system, relay group, multiple function-defined adapter plugs, and measurement module. The PLC control system connects to the engine electronic controller by driving the relay group and via the adapter plug and the bench control cable, for inputting engine control commands and collecting status parameters. The host computer is communicatively connected to the PLC control system and includes STEP7 configuration software for PLC hardware configuration and program writing, and WinCC configuration software for operation command input and status parameter monitoring. The data acquisition system is communicatively connected to the host computer and the PLC control system, and is used to collect the engine's control parameters and status parameters.

2. The electrical control system for the aero-engine test stand as described in claim 1, characterized in that, The relays and adapters in the control cabinet are divided and defined according to the control functions, so that a set of PLC control system and relay group can be compatible with the control functions of different engine models by modifying the hardware address configuration; when adding a new engine model, the control cabinet and its internal PLC control system and relays can be reused directly.

3. The electrical control system for the aero-engine test stand as described in claim 1, characterized in that, The adapter plug includes at least: The first adapter plug is used to transmit the power supplied by the relay driven by the PLC control system to the engine electronic controller. The voltage and current of the power supply are collected by the measurement module and fed back to the PLC control system. The second and fourth adapter plugs are used to transmit bench control commands provided by the relays driven by the PLC control system to the engine electronic controller. The third and fourth adapter plugs are used to transmit the digital status parameters output by the engine to the PLC control system via relay contacts. The fifth adapter is used to connect the analog status parameters output by the engine to the PLC control system or a dedicated testing device. The sixth adapter plug is used to connect the communication signals of the engine electronic controller to the test bench local area network.

4. The electrical control system for the aero-engine test stand as described in claim 1, characterized in that, The bench control cable is used to connect the control cabinet and the engine electronic controller; different engine models are equipped with independently designed bench control cables, and each cable end has a plug corresponding to the function definition of the adapter plug in the control cabinet; when changing the engine model, the corresponding model bench control cable plug is connected to the adapter plug in the control cabinet, without the need to rewire inside the control cabinet.

5. The electrical control system for the aero-engine test bench as described in claim 1, characterized in that, The STEP7 software in the host computer is designed with a modular approach to control programs, arranging the control programs for different engine models in independent functional modules. The corresponding module can be called with one-click operation to achieve rapid switching between engine models. The WinCC software provides separate configuration and operation control interfaces for different engine models, and the corresponding interface can be called with one click through the engine model selection button to achieve rapid switching between the control interfaces of different engine models.

6. An electrical control method for an aero-engine test stand, employing the aero-engine test stand electrical control system as described in any one of claims 1-5, characterized in that, Includes the following steps: Engine control signals are generated via the throttle console; The PLC control system drives the relay group in the control cabinet according to the control logic, and transmits the control commands to the engine electronic controller via the adapter plug and the bench control cable. The engine output status parameters are collected and fed back to the PLC control system through the adapter plug and bench control cable. The host computer receives the operator's control input and sends it to the PLC control system, while also receiving and displaying engine status parameters from the PLC control system. The data acquisition system collects and records engine parameters during the test run.

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