A kind of redundancy instruction control system and method of ground test control system of full-system test bench

Abstract

The application belongs to the technical field of helicopter test, and particularly relates to a full-system test bench ground test operating system redundancy instruction control system and method. The upper computer is connected with two real-time controllers; each real-time controller is provided with two analog input and output modules; the two real-time controllers are connected with two steering engine controllers; each steering engine controller is provided with two servo redundancies; the analog output modules A and B of the real-time controller I respectively output the control instructions of A and B processing redundancies to the servo redundancies A and B of the steering engine controller A; the analog input modules A and B of the real-time controller I simultaneously collect the control instructions of the analog output modules A and B; the analog output modules C and D of the real-time controller II respectively output the control instructions and validity of C and D processing redundancies to the servo redundancies C and D of the steering engine controller B; and the analog input modules C and D of the real-time controller II simultaneously collect the control instructions and validity of the analog output modules C and D.

Description

Technical Field

[0001] This invention belongs to the field of helicopter testing technology, and specifically relates to a redundancy command control system and method for a ground test control system of a full-system test bench. Background Technology

[0002] The test bench control system is mainly used to control the rotor and tail rotor. Its reliability and safety play a crucial role in the successful completion of ground tests.

[0003] The redundant command control of the control system in the ground test state of the whole system test bench has realized the replacement of the redundant control stick system in the cockpit, which greatly improves safety while meeting the functions and performance of the control system, and ensures that the control system is safer and more reliable.

[0004] The hydraulic control system of the ground-based joint test rig consists of a host computer, analog I / O modules, a servo controller, a hydraulic system on the ground test machine, and a hydraulic servo mechanism. The analog I / O modules and servo controller are single-redundant designs, which cannot meet the requirements for high safety and reliability. See the schematic diagram below. Figure 1 . Summary of the Invention

[0005] Objective: This invention provides a redundancy command control system and method for a ground-based test system on a full-system test bench. The command control system of this invention consists of an industrial control computer, two real-time controllers, four analog output modules, four analog input modules, and digital I / O modules. Operators in the control room use a software interface on the industrial control computer to monitor the system, generate power spectrum, and change test status. This invention significantly improves the safety and reliability of the control system, reduces manual workload, increases test efficiency, meets the requirements of different test subjects, and ensures the smooth completion of tests. A simplified system diagram is shown below. Figure 2 .

[0006] Technical solution

[0007] A redundancy command control system for a ground test operation system on a full-system test bench, comprising the following components:

[0008] The host computer and two real-time controllers are connected via network cables; each real-time controller is equipped with two analog input modules and two analog output modules; the two real-time controllers are connected to two servo controllers via analog hardwired connections; each servo controller is equipped with two servo redundancies.

[0009] The analog output modules A and B of the real-time controller I output the control commands and validity of the processing redundancy of A and B respectively and send them to the servo redundancy A and B of the servo controller A; the analog input modules A and B of the real-time controller I simultaneously acquire the control commands and validity of the analog output modules A and B.

[0010] The analog output modules C and D of the real-time controller II output the control commands and validity of the C and D processing redundancy respectively and send them to the servo redundancy C and D of the servo controller B; the analog input modules C and D of the real-time controller II simultaneously acquire the control commands and validity of the analog output modules C and D.

[0011] The servo redundancy A, B, C, and D of the servo controller correspond to the servo control redundancy A, B, C, and D of each servo, respectively.

[0012] Furthermore, the cross control signals A and B output by analog output modules A and B are both output to analog input modules C and D via analog hardwired connections;

[0013] The cross control signals C and D output by analog output modules C and D are both output to analog input modules A and B through analog hardwire.

[0014] Furthermore, servo controller A and servo controller B exchange data for the four servo redundancies: A, B, C, and D.

[0015] Furthermore, the system also includes: a zero-return switch;

[0016] Both real-time controllers I and II are also equipped with digital input modules;

[0017] The zero-return switch is directly connected to the two digital input modules via analog hardwire.

[0018] A zero-return switch is used as a backup emergency control for the host computer. When the host computer crashes, malfunctions, or experiences a communication failure, the zero-return switch enables the servo motor to return to zero, allowing the test machine to stop safely and ensuring test safety.

[0019] Furthermore, the zero-return switch outputs a low level when released and a high level when pressed.

[0020] When the real-time controller's digital input module receives a high-level signal, the real-time controller performs path planning calculations based on the pre-set target command, the actual feedback position of the servo motor, and the operating speed, generating a time-domain sequence command array and periodically sending the command sequence for zero-return control. The zero-return switch performs the zero-return operation when pressed and maintains the current position when released.

[0021] Furthermore, zero-return control has the highest priority. When performing a zero-return operation, if both real-time controller chassis are active, the cross-control active status of the chassis will not be changed. If one of the two real-time controller chassis is cross-controlled inactive, the chassis that is cross-controlled inactive will be set to cross-control inactive to ensure maximum instruction redundancy.

[0022] Furthermore, the host computer sends a valid cross-control signal to the real-time controller. Only when the real-time controller's own cross-control signal is valid can it process the cross-control signal sent from another real-time controller.

[0023] The cross-control command is valid when low and invalid when high. The reason for setting it to invalid when high is that if a real-time controller loses power, its output will go low, and this low-level signal will invalidate another valid chassis. This prevents the host computer from sending valid control commands through the originally valid chassis; control can only be achieved through the homing control program.

[0024] Furthermore, under normal circumstances, the host computer sends the calculated path planning data of each servo motor to the real-time controller via the network cable. The analog output module of the real-time controller sends the instructions to the corresponding A, B, C, and D redundancy of the servo controller via analog hard wires. The servo controller transmits all instructions to each other and performs average processing to serve as the instructions for the A, B, C, and D redundancy servo control of each servo motor.

[0025] When communication between one of the real-time controllers and the host computer is interrupted, the host computer automatically sets the cross-control command to a high level through the real-time controller with normal communication, thus invalidating the chassis of the real-time controller with interrupted communication. At this time, the host computer can send valid commands to the servo controller through the real-time controller with normal communication to ensure the normal operation of the system.

[0026] One cross control signal from each chassis is sent to two acquisition modules in another chassis, and each chassis has two cross control signal outputs. When the result of ORing the four cross control signals received by each chassis is true, that chassis is set to invalid. This increases the reliability of the judgment function and ensures that the servo can be controlled normally.

[0027] Furthermore, each servo controller collects the control commands and their validity for each redundancy, and removes invalid commands. To eliminate the differences between the commands of each redundancy, all valid commands are averaged, and the average result is used as the control command for each redundancy. When the servo loop of a certain redundancy fails, the output of that servo loop is automatically cut off, while other redundancies are unaffected and can perform servo control of the servo normally.

[0028] A redundancy command control method for a ground test control system of a full-system test bench, used to control the system, includes the following steps:

[0029] First: The host computer realizes the input and feedback of rotor and tail rotor pitch commands, actual position feedback and system status display; command synchronization control, command planning and sending, and sending the validity of real-time controller cross control signals;

[0030] Second: The real-time controller realizes the transmission of command time-domain sequences, the acquisition of homing commands, and the planning of homing paths;

[0031] Third: The analog output module implements analog commands and command validity output;

[0032] Fourth: The analog input module enables dual-loop acquisition of commands and acquisition of actual displacement.

[0033] Fifth: Digital input enables the acquisition of power status.

[0034] In summary, the beneficial effects of the present invention are as follows:

[0035] This invention provides a redundant command control method for a ground test state control system of a full-system test bench, which can still output control commands normally even when three command outputs fail, making the entire system more reliable and safe. At the same time, the system has multiple control functions to realize rapid switching between different test states and improve test efficiency. Attached Figure Description

[0036] Figure 1 This is a simplified diagram of the hydraulic control system of the ground-based joint test rig;

[0037] Figure 2 This is a simplified diagram of a redundancy command control system for a ground test state manipulation system on a full-system test bench.

[0038] Figure 3 This is a simplified diagram of a redundancy command control system for a ground test state control system on a full-system test bench (for host computer failures).

[0039] Figure 4 This is a simplified diagram of a redundancy command control system for a ground test state operating system on a full-system test bench (with one unit experiencing a communication failure).

[0040] Figure 5 This is a block diagram of the front interface of the system test bench ground test status control system software. Detailed Implementation

[0041] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0042] In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0043] Furthermore, the terms "installation," "setup," "equipped with," "connection," "linking," and "socketing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0044] A redundant command control system for ground test conditions on a full-system test bench, the key point of which is:

[0045] First, the system consists of a zero-return switch and a host computer arranged on the measurement and control console, as well as two real-time controllers, two servo controllers, and servo motors at the test site.

[0046] Second, the zero-return switch is directly connected to the digital input modules of the two real-time controllers via analog hard wiring, and the host computer and the real-time controllers are connected via network cable;

[0047] Third, each real-time controller includes a real-time module, an 8-slot FPGA chassis, two 32-channel analog input modules, two 16-channel analog output modules, and one 4-channel digital input module;

[0048] Fourth, the analog output module of the real-time controller (chassis 1) is defined as A and B redundancy. It sends the control commands and validity of A and B redundancy to the A and B redundancy of the servo controller through analog hard wiring. At the same time, the commands issued by the A redundancy module are collected by the analog input modules A and B respectively, and the commands issued by the B redundancy module are also collected by the analog input modules A and B respectively.

[0049] Fifth, the analog output module of the real-time controller (chassis 2) is defined as C and D redundancy. It sends the control commands and validity of C and D redundancy to the C and D redundancy of the servo controller through analog hard wiring. At the same time, the commands issued by the C redundancy module are collected by the analog input modules C and D respectively, and the commands issued by the D redundancy module are also collected by the analog input modules C and D respectively.

[0050] Sixth, the crossover control signals from redundancy module A enter analog input modules C and D respectively through analog hardwires; the crossover control signals from redundancy module B also enter analog input modules C and D respectively through analog hardwires; the crossover control signals from redundancy module C enter analog input modules A and B respectively through analog hardwires; the crossover control signals from redundancy module D also enter analog input modules A and B respectively through analog hardwires.

[0051] Seventh, the A, B, C, and D redundancies of the servo controller correspond to the servo control of the A, B, C, and D redundancies of each servo, and the commands of each redundancy are transmitted to each other via a bus.

[0052] Eighth, the measurement and control room uses a zero-return switch as a backup emergency control for the host computer. When the host computer crashes, malfunctions, or experiences a communication failure, the zero-return switch enables the servo motor to return to zero, allowing the test machine to stop safely and ensuring test safety.

[0053] Ninth, during homing control, when the real-time controller's digital input module receives a high-level signal, the real-time controller performs path planning calculations according to the pre-set target command, the actual feedback position of the servo motor, and the running speed to generate a time-domain sequence command array and periodically sends the command sequence to perform homing control; when the homing switch is pressed, the homing operation is performed, and when it is released, the current position remains unchanged; under any circumstances, the homing operation task of the operating console is executed first. When performing the homing operation, if both real-time controller chassis are effective, the cross-control effective state of the chassis will not be changed. If there is a chassis that is cross-controlled and invalid, the chassis that is controlled and invalid will be set to cross-control invalid to ensure maximum command redundancy;

[0054] Tenth, two real-time controllers are used and cross-validation control is possible. The host computer sends a valid cross-control signal to the real-time controller, and the real-time controller can only process the cross-control signal sent by the other real-time controller when the cross-control signal of the real-time controller is valid.

[0055] Eleventh, when the system is working normally, the host computer sends the calculated path planning data of each servo motor to the real-time controller via network cable. The analog output module of the real-time controller sends the commands to the corresponding A, B, C, and D redundancy of the servo controller via analog hardwired connections. The servo controller transmits all commands to each other and performs average processing, then uses these commands as the A, B, C, and D redundancy servo control commands for each servo motor. See Figure 2 ;

[0056] Twelfth, when the system's host computer malfunctions, the system can only be controlled via the zero-return switch. See details... Figure 3 ;

[0057] Thirteenth, when communication between one of the real-time controllers and the host computer is interrupted, the host computer can automatically set the cross-control command to a high level through the real-time controller with normal communication, thus invalidating the chassis of the real-time controller with interrupted communication. At this time, the host computer can send valid commands to the servo controller through the real-time controller with normal communication, ensuring the normal operation of the system. Here, the cross-control command is valid when it is low and invalid when it is high. The reason for setting it to invalid when it is high is that if a real-time controller loses power, its output will become low, and this low-level signal will cause another valid chassis to be invalidated, thus preventing the host computer from sending valid control commands through the originally valid chassis; it can only control through the zero-return control program. One cross-control signal from each chassis enters two acquisition modules of another chassis, and each chassis has two cross-control signal outputs. When the OR operation of the four cross-control signals received by each chassis is true, the chassis is invalidated, increasing the reliability of the judgment function and ensuring that the servo can be controlled normally; see Figure 4 When performing a zero-return operation under this fault condition, see... Figure 3 ;

[0058] Fourteenth, a dual-loop monitoring system for analog command output is adopted. To avoid false alarms caused by acquisition module failure, two different acquisition modules are used to acquire the output command and compare it with the command signal sent by the computer. If the error is within the threshold range, it is considered valid. After performing an OR operation on the two sets of comparison results, a valid signal is output. This valid signal is ANDed with the valid signal of the chassis and output as a valid signal level. The validity of the valid command signal is expressed as a 5V high level output of all servo command output voltages of a certain redundancy. The invalid command signal is output as a low level. When the command is invalid, all servo commands of that redundancy are invalid. This simplifies the complexity of validity judgment, makes it easier to implement, and increases system reliability.

[0059] Fifteenth, the two controllers only synchronize when executing tasks. To ensure the consistency of instructions sent by the two real-time controllers, a task synchronization method is adopted. After receiving the running instruction sent by the host computer, the two controllers start counting. The counting results are transmitted to the host computer through the network. The computer judges whether their synchronization is within the set synchronization error range based on the count values ​​of the two controllers. If it is within the error range, no adjustment is made. If it exceeds the error range, the controller with the larger count value waits and holds the instruction until it reaches the error range, and then synchronizes and continues to run. After the target instruction is executed, the task ends and the synchronization function exits.

[0060] Sixteenth, instruction hold function during instruction mutation (threshold adjustable); when the absolute value of the difference between the newly received instruction and the previous instruction in the real-time controller chassis is greater than the threshold, the new instruction is not accepted, the original instruction is held, and the host computer is notified that the current instruction sent is abnormal; to prevent abnormal instruction mutation from increasing the risk of experimentation.

[0061] Seventeenth, each servo controller collects the control commands and their validity for each redundancy and removes invalid commands. To eliminate the differences between the commands of each redundancy, all valid commands are averaged and the average result is used as the control command for each redundancy. When the servo loop of a certain redundancy fails, the output of that servo loop is automatically cut off, while the remaining redundancies are unaffected and can perform servo control of the servo normally.

[0062] Includes the following steps:

[0063] First: The host computer realizes the input and feedback of rotor and tail rotor pitch commands, actual position feedback and system status display; command synchronization control, command planning and sending, and sending the validity of real-time controller cross control signals;

[0064] Second: The real-time controller realizes the transmission of command time-domain sequences, the acquisition of homing commands, and the planning of homing paths;

[0065] Third: The analog output module implements analog commands and command validity output;

[0066] Fourth: The analog input module enables dual-loop acquisition of commands and acquisition of actual displacement.

[0067] Fifth: Digital input enables the acquisition of power status.

[0068] Specific implementation plan:

[0069] 1) The host computer completes instruction planning and sending, task synchronization control, etc.;

[0070] 2) Real-time controller: Implements deterministic control, reliable and efficient Ethernet communication, completes the timed transmission of timing sequence commands, completes the input and output of analog and digital quantities, data exchange, command validity judgment, cross-control between chassis validity and validity control, command holding when command changes suddenly (threshold adjustable), etc.

[0071] 3) Analog output module; the number of analog channels, output current, voltage, etc. meet the requirements, including all servo motors and interconnection equipment;

[0072] 4) Analog input module; command output dual loop acquisition, servo motor actual position feedback acquisition;

[0073] 5) Digital input module: power status acquisition, etc.

[0074] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A redundancy command control system for a ground test operation system of a full-system test bench, characterized in that: The system consists of the following components: The host computer and two real-time controllers are connected via network cables; each real-time controller is equipped with two analog input modules and two analog output modules; the two real-time controllers are connected to two servo controllers via analog hardwired connections; each servo controller is equipped with two servo redundancies. The analog output modules A and B of the real-time controller I output the control commands and validity of the processing redundancy of A and B respectively, and send them to the servo redundancy A and B of the servo controller A; The analog output modules C and D of the real-time controller II output the control commands and validity of the C and D processing redundancy respectively and send them to the servo redundancy C and D of the servo controller B; The servo redundancy A, B, C, and D of the servo controller correspond to the servo control redundancy A, B, C, and D of each servo, respectively.

2. The system according to claim 1, characterized in that: The analog input modules A and B of the real-time controller I simultaneously acquire the control commands and validity of the analog output modules A and B; The analog input modules C and D of the real-time controller II simultaneously acquire the control commands and validity of the analog output modules C and D; The cross control signals A and B output by analog output modules A and B are both output to analog input modules C and D through analog hardwired connections; the cross control signals C and D output by analog output modules C and D are both output to analog input modules A and B through analog hardwired connections.

3. The system according to claim 2, characterized in that: Servo controller A and servo controller B exchange data for four servo redundancy parameters: A, B, C, and D.

4. The system according to claim 3, characterized in that: The system also includes: a zero-return switch; Both real-time controllers I and II are also equipped with digital input modules; The zero-return switch is directly connected to the two digital input modules via analog hardwire.

5. The system according to claim 4, characterized in that: The zero-return switch outputs a low level when it is released and a high level when it is pressed. The real-time controller's digital input module performs zero-return control when it receives a high-level signal.

6. The system according to claim 5, characterized in that: Zeroing control has the highest priority.

7. The system according to claim 6, characterized in that: The host computer sends a valid cross control signal to the real-time controller. Only when the real-time controller's own cross control signal is valid can it process the cross control signal sent by another real-time controller. The cross control command is valid when it is low and invalid when it is high.

8. The system according to claim 7, characterized in that: Under normal circumstances, the host computer sends the calculated path planning data of each servo motor to the real-time controller via network cable. The analog output module of the real-time controller sends the instructions to the corresponding A, B, C, and D redundancy of the servo controller via analog hard wire. The servo controller transmits all instructions to each other and performs average processing to serve as the instructions for the A, B, C, and D redundancy servo control of each servo motor. When communication between one of the real-time controllers and the host computer is interrupted, the host computer automatically sets the cross-control command to a high level through the real-time controller with normal communication, thus invalidating the chassis of the real-time controller with interrupted communication. At this time, the host computer can send valid commands to the servo controller through the real-time controller with normal communication to ensure the normal operation of the system. One cross control signal from each chassis enters two acquisition modules in another chassis, and each chassis has two cross control signal outputs; when the result of ORing the four cross control signals received by each chassis is true, that chassis is set to invalid.

9. The system according to claim 8, characterized in that: Each servo controller collects control commands and their validity for each redundancy, removes invalid commands, averages all valid commands, and uses the average result as the control command for each redundancy. When a servo loop in a redundancy fails, the output of that servo loop is automatically cut off, while other redundancies remain unaffected and can perform normal servo control of the servo.

10. A redundancy command control method for a ground test control system of a full-system test bench, used to control the system described in any of the preceding claims, characterized in that: Includes the following steps: First: The host computer realizes the input and feedback of rotor and tail rotor pitch commands, actual position feedback and system status display; command synchronization control, command planning and sending, and sending the validity of real-time controller cross control signals; Second: The real-time controller realizes the transmission of command time-domain sequences, the acquisition of homing commands, and the planning of homing paths; Third: The analog output module implements analog commands and command validity output; Fourth: The analog input module enables dual-loop acquisition of commands and acquisition of actual displacement. Fifth: Digital input enables the acquisition of power status.

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