Engine test bench integrated command system

Abstract

This invention relates to the field of engine testing system technology and discloses an integrated command system for an engine test bench, comprising: a time synchronization unit and a data video processing unit. The time synchronization unit is networked with the process measurement system and camera system of the engine test bench via a network switch. The first network port of the data video processing unit is connected to the process measurement system, and the second network port of the data video processing unit is connected to the camera system via the network switch. By setting up the time synchronization unit and the data video processing unit, the time synchronization unit provides a unified absolute time reference for the process measurement system and the camera system. The data video processing unit adopts a dual-port independent connection design, receiving measurement parameters and video streams in real time, and performing precise matching according to timestamps to automatically generate a fused image integrating parameters and video. This eliminates the need for test personnel to switch between multiple screens for observation, significantly improving test monitoring efficiency and operational convenience.

Description

Technical Field

[0001] This invention relates to the field of engine testing system technology, and more specifically to an integrated command system for an engine test bench. Background Technology

[0002] Throughout the entire engine testing process, the coordinated observation and analysis of test videos and key measurement parameters are crucial for the smooth conduct of the test, fault location, and engine performance evaluation. During the test preparation phase, the commander needs to determine the subsystem's operating status through videos and parameters; during the ignition phase, real-time monitoring of the test dynamics is required; and after the test, videos and parameters need to be analyzed synchronously to verify the test results and identify any anomalies.

[0003] In existing technologies, the video monitoring system and measurement system of an engine test bench are two independent systems: the video monitoring system consists of a front-end camera, fiber optic transmission equipment, a hard disk recorder, and a large-screen display, while the measurement system consists of front-end sensors, transmission cables, isolation modules, junction boxes, a pre-controller, and a terminal computer. The terminal display and data storage of the two systems are independent; video data is displayed on a dedicated screen and stored on the hard disk recorder, while measurement parameters are displayed on another screen and stored on the terminal computer. This presents two major problems: first, during the test, the commander and data analysts need to frequently switch their gaze to observe the video and parameters, making real-time collaborative judgment impossible; second, in the post-test data analysis phase, it is difficult to achieve precise synchronization between the video footage and the measurement parameters, significantly reducing data analysis efficiency and fault location speed. Summary of the Invention

[0004] This invention provides an integrated command system for engine test benches to solve the problems of separation between video and measurement systems, low efficiency in collaborative observation and analysis, and high difficulty in system modification in existing engine test benches.

[0005] This invention provides an integrated command system for an engine test bench, the system comprising: a time synchronization unit and a data / video processing unit, wherein... The time synchronization unit is connected to the process measurement system and camera system of the engine test bench via a network switch. The time synchronization unit is used to provide a unified absolute time reference for the process measurement system and camera system. The first network port of the data video processing unit is connected to the process measurement system, and the second network port of the data video processing unit is connected to the camera system through a network switch. The data video processing unit is used to receive the measurement parameters output by the process measurement system and the video stream output by the camera system, and match the video stream with the measurement parameters according to the timestamp to generate a fused screen display integrating parameters and video.

[0006] This invention provides an integrated command system for an engine test bench. By setting up a time synchronization unit and a data video processing unit, the time synchronization unit provides a unified absolute time reference for the process measurement system and the camera system, ensuring that the measurement parameters and video streams have highly accurate timestamp alignment. This fundamentally solves the problem of data and video being out of sync and difficult to match afterward in traditional test systems. The data video processing unit adopts a dual-port independent connection design. The first port is directly connected to the process measurement system for dedicated transmission of measurement parameters, while the second port obtains the video stream through a switch, achieving physical isolation of the data link, effectively avoiding network interference and data conflicts, and improving system stability. The data video processing unit can receive measurement parameters and video streams in real time, and accurately match them according to the timestamps, automatically generating a fused image of parameters and video, eliminating the need for test personnel to switch between multiple screens for observation, significantly improving test monitoring efficiency and operational convenience. This invention achieves minimal invasive modification without altering the original test system hardware and core programs. The overall structure is simple, with strong real-time performance and high reliability. It can be widely applied to real-time monitoring, process playback, and fault tracing of engine test benches, and has strong practicality and versatility.

[0007] In one optional implementation, the data video processing unit includes: an integrated command host, a host computer for the acquisition system, and an NI acquisition controller, wherein, The first network port of the integrated command host is connected to the host computer of the acquisition system, the second network port of the integrated command host is connected to the camera system through the network switch, and the host computer of the acquisition system is connected to the NI acquisition controller; The NI acquisition controller is used to acquire the measurement parameters of the process measurement system and transmit the measurement parameters to the host computer of the acquisition system; the integrated command host receives the measurement parameters transmitted by the host computer of the acquisition system through the first network port, and at the same time receives the video stream transmitted by the camera system through the second network port.

[0008] In one optional implementation, the host computer of the acquisition system sends the measurement parameters to the integrated command host via the UDP protocol.

[0009] In one optional implementation, the integrated command host, the data acquisition system host computer, and the NI data acquisition controller all adopt a dual-network port structure design.

[0010] In one optional implementation, the time synchronization unit uses a BeiDou time server.

[0011] In one alternative implementation, the integrated command host is developed based on Qt and OpenCV and adopts a multi-threaded parallel architecture.

[0012] In one optional embodiment, the data video processing unit further includes a display unit, which is used to display an overlay display area below the video screen. The overlay display area is used to display measurement parameters, real-time curves, time progress bars, remaining liquid level information, and alarm status.

[0013] In one optional implementation, the data video processing unit further includes a memory for real-time recording and saving of the merged footage. Attached Figure Description

[0014] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0015] Figure 1 This is a schematic block diagram of an integrated command system for an engine test bench according to an embodiment of the present invention; Figure 2 This is a schematic diagram of an integrated command system for an engine test bench according to an embodiment of the present invention. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, 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.

[0017] It is understood that before using the technical solutions disclosed in the various embodiments of the present invention, users should be informed of the types, scope of use, and usage scenarios of the personal information involved in the present invention and their authorization should be obtained in accordance with relevant laws and regulations through appropriate means.

[0018] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0019] like Figure 1As shown, this invention provides an integrated command system for an engine test bench, comprising: a time synchronization unit and a data video processing unit. The time synchronization unit is networked with the process measurement system and camera system of the engine test bench via a network switch. The time synchronization unit provides a unified absolute time reference for both the process measurement system and the camera system. The first network port of the data video processing unit is connected to the process measurement system, and the second network port of the data video processing unit is connected to the camera system via the network switch. The data video processing unit receives measurement parameters output from the process measurement system and video streams output from the camera system, and matches the video streams with the measurement parameters according to timestamps to generate a fused display of the parameters and video.

[0020] Specifically, the time synchronization unit is connected to the process measurement system and camera system of the engine test bench via a network switch to provide a unified absolute time reference for the process measurement system and the camera system. This ensures that the measurement parameters output by the process measurement system and the video stream output by the camera system both carry aligned absolute timestamps, providing a time reference guarantee for subsequent data matching.

[0021] The data video processing unit is equipped with a first network port and a second network port. The first network port of the data video processing unit is directly connected to the process measurement system of the engine test bench and is used to receive the measurement parameters output by the process measurement system. The second network port of the data video processing unit is connected to the camera system through a network switch and is used to receive the real-time video stream output by the camera system.

[0022] The data video processing unit separately receives and processes the two data streams in parallel. Based on the absolute timestamp, it accurately matches and aligns the video streams and measurement parameters at the corresponding times. It integrates and renders the key measurement parameters and video images into a unified image, generating a fused screen that displays the parameters and video on the same screen. This enables synchronous observation, real-time analysis, and fault diagnosis of video images and measurement parameters during engine testing.

[0023] This system is built on the basis of the original process measurement system and camera system using a bypass access method, so as to achieve integrated command of test data and video with minimal modification, without affecting the independent operation and data acquisition and storage functions of the original system.

[0024] This invention provides an integrated command system for an engine test bench. By setting up a time synchronization unit and a data video processing unit, the time synchronization unit provides a unified absolute time reference for the process measurement system and the camera system, ensuring that the measurement parameters and video streams have highly accurate timestamp alignment. This fundamentally solves the problem of data and video being out of sync and difficult to match afterward in traditional test systems. The data video processing unit adopts a dual-port independent connection design. The first port is directly connected to the process measurement system for dedicated transmission of measurement parameters, while the second port obtains the video stream through a switch, achieving physical isolation of the data link, effectively avoiding network interference and data conflicts, and improving system stability. The data video processing unit can receive measurement parameters and video streams in real time, and accurately match them according to the timestamps, automatically generating a fused image of parameters and video, eliminating the need for test personnel to switch between multiple screens for observation, significantly improving test monitoring efficiency and operational convenience. This invention achieves minimal invasive modification without altering the original test system hardware and core programs. The overall structure is simple, with strong real-time performance and high reliability. It can be widely applied to real-time monitoring, process playback, and fault tracing of engine test benches, and has strong practicality and versatility.

[0025] In one alternative implementation, such as Figure 2 As shown, the data video processing unit includes: an integrated command host, a host computer for the acquisition system, and an NI acquisition controller. The first network port of the integrated command host is connected to the host computer for the acquisition system, and the second network port of the integrated command host is connected to the camera system via a network switch. The host computer for the acquisition system is connected to the NI acquisition controller. The NI acquisition controller is used to acquire measurement parameters from the process measurement system and transmit these parameters to the host computer for the acquisition system. The integrated command host receives the measurement parameters transmitted from the host computer for the acquisition system through its first network port and simultaneously receives the video stream transmitted from the camera system through its second network port.

[0026] Specifically, when the system is in normal operation, the NI acquisition controller acquires key measurement parameters such as pressure, temperature, and flow rate from the process measurement system in real time. Simultaneously, it synchronizes with the time synchronization unit, ensuring that each acquired parameter carries a corresponding absolute timestamp. This timestamped parameter data is then transmitted to the acquisition system's host computer in real time. The host computer runs a UDP data transmission program written in LabVIEW. This program runs independently in a loop, without affecting the main program's data acquisition, display, and storage functions. It transmits 12 important measurement parameters to the integrated command host in real time via the UDP protocol. At the same time, the camera system acquires real-time video streams from the test site, also synchronizing with the time synchronization unit to ensure that each frame in the output video stream carries an absolute timestamp.

[0027] The integrated command host connects to the network switch via a second network port to receive real-time video streams from the test site captured by the camera system. The camera system uses Hikvision low-latency cameras. Hikvision's third-party development tool SDK has rich interfaces, allowing direct access to the cameras, streaming, and obtaining timestamps. Hikvision cameras are network cameras, and their latency is greater than the measured data. The on-site cameras are low-latency 25fps cameras.

[0028] The integrated command host buffers the received measurement parameters for a preset duration (e.g., 1 second) and simultaneously parses the video stream frame by frame, extracting the absolute timestamp of each frame. Based on timestamp matching rules, the measurement parameters at the corresponding moment are precisely aligned with the video frames. Parameter values, over-limit alarm indicators, test status, and other information are overlaid onto the video screen, generating a fused image integrating parameters and video. This image is then output to the display terminal, enabling visualized integrated command and real-time monitoring of the engine test process.

[0029] In one alternative implementation, the host computer of the data acquisition system sends the measurement parameters to the integrated command host via the UDP protocol.

[0030] Specifically, the host computer of the acquisition system has a built-in UDP data transmission program written in LabVIEW. This program runs in an independent loop and does not affect the data acquisition, display, and storage functions of the main program of the host computer. After acquiring multiple key measurement parameters from the process measurement system through the NI acquisition controller, the host computer packages the parameters according to a preset communication format and sends them to the integrated command host in real time via the UDP protocol. The integrated command host receives the measurement parameters through the first network port, completing the high-speed and stable transmission of the parameters and providing data support for subsequent timestamp matching and fusion display of video and parameters.

[0031] Furthermore, the host computer of the acquisition system synchronously stores the key parameters of the process measurement system, which are acquired in real time through the NI acquisition controller and carry absolute timestamps, into the database, completing the full and persistent retention of the test data. The integrated command host no longer directly receives UDP data sent by the acquisition system, but instead reads the required key measurement parameters from the database on demand, and performs subsequent operations such as video fusion, interface display, over-limit alarm, and data storage based on the read data. The camera system synchronizes the clock of the synchronization unit, acquires real-time video streams from the test site, and adds an absolute timestamp to each frame. The video stream is then transmitted to the integrated command host through a network switch. The integrated command host parses the received video stream frame by frame, extracts the absolute timestamp of each frame, and actively queries the database based on the timestamp to retrieve the measurement parameters at the corresponding time, completing the precise time alignment between the measurement parameters and the video frames. Subsequently, the parameter values, over-limit alarm indicators, test operation status, and other information are overlaid and drawn onto the corresponding video screen to generate a fused screen integrating parameters and video, which is then output to the display terminal to achieve visual monitoring of the test process. By adopting a decoupled architecture where the acquisition end writes to the database and the command end reads from the database, data acquisition and data processing can be made independent of each other, avoiding the stability risks caused by direct coupling between the acquisition system and the integrated command system, and improving the overall reliability and scalability of the system.

[0032] In one optional implementation, the integrated command host, the data acquisition system host computer, and the NI data acquisition controller all adopt a dual-network port design.

[0033] Specifically, the first network port of the integrated command host is directly connected to the first network port of the acquisition system's host computer for unidirectional, dedicated transmission of measurement parameters, achieving physical isolation of measurement data transmission. The second network port of the acquisition system's host computer is connected to the first network port of the NI acquisition controller, used to receive multiple measurement parameters uploaded by the NI acquisition controller. The second network port of the NI acquisition controller is connected to the system's local area network (LAN) via a network switch, primarily used to receive high-precision timing signals from the time synchronization unit, ensuring that the NI acquisition controller, integrated command host, and camera system maintain a unified absolute time reference. This ensures that the acquired measurement parameters and video streams have strictly aligned timestamps, providing time assurance for accurate matching of subsequent data and video. The second network port of the integrated command host is connected to the LAN via a network switch, used to acquire the real-time video stream output by the camera system and achieve system time synchronization. Through this dual-network port connection architecture, the measurement parameter transmission link can be isolated from network services such as video streams and time synchronization, avoiding data interference and improving system operational stability and data transmission reliability.

[0034] In one alternative implementation, the time synchronization unit employs a BeiDou time server.

[0035] Specifically, the BeiDou time server is connected to the system's local area network via a network switch, providing a unified, high-precision absolute time reference for the integrated command host, the acquisition system's host computer, the NI acquisition controller, and the camera system. The time server uses the NTP network time synchronization protocol to calibrate the clocks of each device, ensuring that time errors between all system devices are controlled within a preset range. This guarantees that the measurement parameters uploaded by the NI acquisition controller and the video stream output by the camera system carry aligned absolute timestamps, providing a reliable time reference for the integrated command host to achieve precise matching between measurement parameters and video footage.

[0036] Furthermore, the time server adopts a high-precision time server with BeiDou time synchronization, model TH-MTB11, which supports BeiDou satellite time synchronization, PPS time synchronization accuracy is better than 20ns, supports IRIG-B code signal input, demodulation synchronization error is less than 100ns, NTP network time synchronization accuracy is better than 10ms, and the time autonomous maintenance deviation is less than 20μs within 24 hours.

[0037] Furthermore, this system utilizes an NI real-time synchronization card to achieve high-precision time synchronization with the NI acquisition controller, ensuring a stable and reliable time reference for measurement parameter acquisition. Hikvision cameras and the time server perform timed clock calibration at 1-minute intervals to ensure that the timestamps of the camera's output video stream are consistent with the system reference. Through these time synchronization and timed calibration mechanisms, the system's absolute time calibration accuracy can reach 1ms, enabling high-precision time alignment between measurement parameters and video footage, providing a reliable guarantee for the fusion and display of data and images.

[0038] In one alternative implementation, the integrated command host is developed based on Qt and OpenCV and adopts a multi-threaded parallel architecture.

[0039] Specifically, the integrated command and control host software adopts a modular and scalable framework design, supports multi-threaded synchronous and asynchronous management and distributed network communication, and its universal interface can be adapted to different types of camera equipment. The software development and compilation environment is: Qt 5.15.x, Visual Studio 2019, CMake, and OpenCV libraries.

[0040] To ensure smooth video streaming and real-time system performance, the program adopts a multi-threaded concurrent processing architecture, allocating core modules such as UDP data acquisition and parsing, video stream acquisition and parsing, image synthesis, image display, and image storage to independent threads for parallel execution. Each thread runs independently and does not interfere with the others.

[0041] The integrated command host buffers the acquired UDP measurement parameters for 1 second. The system operates at a frame rate of 25 frames per second, reading one video frame every 40ms and simultaneously parsing the absolute timestamp corresponding to that frame. Then, it matches the measurement parameters that match the current timestamp in the buffered UDP parameters, completing the precise alignment and fusion of the video frame and the measurement data.

[0042] Furthermore, the integrated command host adopts a high-performance graphics workstation, with an Intel Core i9-14900K processor, an RTX A5500-24G graphics card, and a dual-network port design.

[0043] In one optional implementation, the data video processing unit further includes a display unit, which displays an overlay display area below the video screen. The overlay display area displays measurement parameters, real-time curves, time progress bars, remaining liquid level information, and alarm status.

[0044] Specifically, the integrated command host sets up an overlay display area below the video screen. This area is a rectangular area of ​​1920×170 pixels with a transparency of 0.4 (which can be flexibly adjusted according to the actual use scenario). While ensuring that the parameters and graphics are clearly displayed, it does not obscure the core screen of the test video and does not affect the integrity of the video observation.

[0045] The system converts the 12 key measurement parameters collected into string format and displays them neatly in the overlay area in the form of "parameter name: parameter value" using a 4-column, 3-row layout. To improve the comfort of human observation, the parameter refresh rate is set to twice per second.

[0046] The system features a tiered alarm function for key parameters. Upon startup at the zero point of the test, it operates according to the following rules: when the temperature parameter Ts > 300℃, the corresponding value is highlighted in red; when the pressure parameter Ps > P0MPa, the corresponding value is highlighted in red; the pressure parameters Pc, Pio, Pif, and Pim have their respective preset baseline values ​​P1, P2, P3, and P4 ± 0.1 as upper and lower limit thresholds, respectively. Values ​​above the upper limit are displayed in red, and values ​​below the lower limit are displayed in yellow. Wherein, Ts represents steam temperature, Ps represents steam pressure, Pc represents chamber pressure, Pio represents oxygen injection pre-pressure, Pif represents alcohol injection pre-pressure, and Pim represents water injection pre-pressure.

[0047] The system supports real-time monitoring of tank levels and remaining time: the initial total amount of alcohol and liquid oxygen tanks is pre-entered, and the fuel consumption is calculated in real time based on flow parameters. The current remaining level is dynamically displayed and presented intuitively in the form of a progress bar. At the same time, the remaining available time is estimated in real time based on the consumption rate and prompts are given. The system can also be directly connected to a level gauge and the measured data from the level gauge can be used for display and calculation.

[0048] The system features igniter, water system, and engine start-up status indication functions: when Pgc > P0', the igniter is considered to have started normally, and the corresponding status point is displayed in green; when PicPim > P1', the water system is considered to have started normally, and the corresponding status point is displayed in green; when Pc > P2', the engine is considered to have started normally, and the corresponding status point is displayed in green. The system displays the test progress using an arc-shaped timeline, with the Pc parameter as the central reference. After the engine starts, the arc-shaped timeline scrolls synchronously proportionally to the test progress. Here, Pgc represents the igniter chamber pressure, and P0', P1', and P2' represent specified pressure points.

[0049] The system can plot real-time curves of two key pressure parameters, Pgc and Pc. The curves support scrolling display for 40 seconds, and the maximum and minimum values ​​of Pc and Pgc within the current time period are displayed synchronously in the upper right corner of the curve area, which makes it easy for testers to quickly grasp the trend of parameter changes.

[0050] In one optional implementation, the data video processing unit further includes a memory for real-time recording and saving of the merged images.

[0051] Specifically, the memory is connected to the integrated command host and is used to record and save the display screen after the measurement parameters and video images are fused in real time. The stored data can be used for test process playback, post-test data analysis and fault location and tracing, ensuring that the test data is complete and traceable.

[0052] This system supports camera devices with different frame rates. When using a camera with a frame rate of 25 frames per second, the system simultaneously reads and analyzes UDP measurement parameters and performs image fusion while acquiring the video stream, storing the synthesized image in real time at a rate of 25 frames per second. To avoid the parameter values ​​refreshing too quickly and affecting the observation effect, the parameter values ​​on the display interface are updated twice per second. When using a high-definition camera with a frame rate of 50 frames per second, the system can store the fused image in real time at a rate of 50 frames per second. In actual use, it is stable and reliable, meeting the high-definition recording and real-time display requirements of the engine test bench.

[0053] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. An integrated command system for an engine test bench, characterized in that, The system includes: a time synchronization unit and a data video processing unit, wherein... The time synchronization unit is connected to the process measurement system and camera system of the engine test bench via a network switch. The time synchronization unit is used to provide a unified absolute time reference for the process measurement system and camera system. The first network port of the data video processing unit is connected to the process measurement system, and the second network port of the data video processing unit is connected to the camera system through a network switch. The data video processing unit is used to receive the measurement parameters output by the process measurement system and the video stream output by the camera system, and match the video stream with the measurement parameters according to the timestamp to generate a fused screen display integrating parameters and video.

2. The engine test bed integrated command system according to claim 1, characterized by, The data video processing unit includes: an integrated command host, a host computer for the acquisition system, and an NI acquisition controller, wherein... The first network port of the integrated command host is connected to the host computer of the acquisition system, the second network port of the integrated command host is connected to the camera system through the network switch, and the host computer of the acquisition system is connected to the NI acquisition controller; The NI acquisition controller is used to acquire the measurement parameters of the process measurement system and transmit the measurement parameters to the host computer of the acquisition system; the integrated command host receives the measurement parameters transmitted by the host computer of the acquisition system through the first network port, and at the same time receives the video stream transmitted by the camera system through the second network port.

3. The engine test bed integrated command system according to claim 2, characterized in that, The host computer of the acquisition system sends the measurement parameters to the integrated command host via the UDP protocol.

4. The engine test bed integrated command system according to claim 2, characterized by, The integrated command host, the host computer of the acquisition system, and the NI acquisition controller all adopt a dual-network port structure design.

5. The engine test bed integrated command system of claim 1, wherein The time synchronization unit uses a BeiDou time server.

6. The engine test bed integrated command system according to claim 2, wherein The integrated command host is developed based on Qt and OpenCV and adopts a multi-threaded parallel architecture.

7. The engine test bed integrated command system of claim 2, wherein The data video processing unit further includes a display unit, which is used to display an overlay display area below the video screen. The overlay display area is used to display measurement parameters, real-time curves, time progress bars, remaining liquid level information, and alarm status.

8. The engine test bed integrated command system according to claim 7, characterized in that, The data video processing unit further includes a memory, which is used to record and save the fused images in real time.

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