Control system for medium-pressure shaft generator of ship

Abstract

The utility model discloses a control system of a medium-pressure shaft belt generator for a ship. The control system comprises a monitoring module which is electrically connected with the medium-pressure shaft belt generator, monitors the operation state of the medium-pressure shaft belt generator, carries out data collection, and generates a monitoring signal based on the data; the control platform is in communication connection with the monitoring module to receive the monitoring signal and process the monitoring signal to generate an operation signal; the man-machine interaction module is in communication connection with the control platform through the switch according to a preset communication protocol so as to receive the operation signal, display the operation signal to a user in a preset mode and receive a control instruction of the user, and the man-machine interaction module transmits the control instruction to the control platform through the switch according to the preset communication protocol; the control platform generates a control signal based on the control instruction and transmits the control signal to the monitoring module, and the monitoring module controls the medium-pressure shaft belt generator based on the control signal. The system provides a more efficient and safer control solution for the power system of the ship.

Description

Technical Field

[0001] This utility model relates to the field of marine shaft-driven generator technology, and in particular to a control system for a marine intermediate-pressure shaft-driven generator. Background Technology

[0002] The main shaft (main engine shafting), a crucial component of a ship's propulsion system, transmits power from the main engine to the propeller. The propeller's axial thrust is then transmitted to the entire hull, propelling the ship's navigation. The shaft-driven generator (also known as the main shaft generator) utilizes the main engine's rotation to drive its rotor, generating electricity. This electricity is then converted to frequency and supplied to the ship's power station system. It effectively utilizes excess energy from the main engine's rotation, improving main engine efficiency and reducing the frequency of starting independent diesel generators or other dedicated generators, thus achieving overall energy conservation for the ship.

[0003] Shaft-driven generators are typically installed in the unused space in the middle of a ship's main shaft, with their rotors rotating coaxially with the shaft. The ship's shaft-driven generator system, also known as the shaft generator system or shaft engine system, is driven by the ship's main engine, utilizing the main engine's surplus power to achieve energy savings. The use of main engine shaft-driven generators has been applied in small and medium-sized ships since the era of DC power systems. With the development of power electronics technology, shaft-driven generators, as an effective means of saving operating costs and improving engine room management and operating conditions, have attracted attention from the shipbuilding and shipping industries worldwide due to their unique advantages. In ship power generation systems, the medium-voltage shaft-driven generator (where medium voltage refers to approximately 11kV) is a key component, responsible for providing a stable and reliable power supply to meet the ship's operational and load requirements. With continuous technological evolution, the control requirements for ship medium-voltage shaft-driven generators are becoming increasingly stringent, including higher levels of automation, more stable operating performance, and more flexible maintenance capabilities. Traditional PLC control systems, such as the Siemens S7-300 series, while performing excellently in small and medium-sized applications, are gradually showing their limitations in some ship applications. These limitations include limited processing power, communication protocols incompatible with modern needs, limited human-machine interface functionality, and lack of support for advanced programming tools, all of which restrict the system's scalability and compatibility. Therefore, upgrading the control system of the ship's intermediate-pressure shaft generator to improve its performance and efficiency becomes particularly important. Utility Model Content

[0004] This application aims to at least partially address one of the technical problems in the related art.

[0005] According to one aspect of this utility model, a control system for a ship's intermediate-pressure shaft-driven generator is provided. The intermediate-pressure shaft-driven generator is disposed between the main engine and the propeller, and is mounted on the ship's main shaft. The rotor of the intermediate-pressure shaft-driven generator is coaxially fixedly connected to the main shaft. The control system comprises: a monitoring module electrically connected to the intermediate-pressure shaft-driven generator, which monitors the operating status of the generator and collects data, and generates monitoring signals based on the data; a control platform communicating with the monitoring module via a switch according to a predetermined communication protocol to receive the monitoring signals and processes the monitoring signals to generate operating signals; and a human-machine interface module communicating with the control platform via the switch according to the predetermined communication protocol to receive the operating signals, display the operating signals to a user in a predetermined mode, and receive control commands from the user. The human-machine interface module transmits the control commands to the control platform via the switch according to the predetermined communication protocol. The control platform generates control signals based on the control commands and transmits the control signals to the monitoring module. The monitoring module controls the intermediate-pressure shaft-driven generator based on the control signals.

[0006] Preferably, the control platform includes a main control unit and a slave control unit. The slave control unit receives field signals sensed by sensors and provides the field signals to the main control unit. The main control unit receives the monitoring signals and the field signals, and processes the monitoring signals and the field signals to generate the operating signals.

[0007] Preferably, the field signals sensed by the sensor include signals indicating the temperature of the intermediate-pressure shaft-driven generator, and the monitoring signals include signals indicating the operating status of the cooling water circulation system of the intermediate-pressure shaft-driven generator.

[0008] Preferably, the main control unit receives the monitoring signal and the field signal, determines whether the monitoring signal is greater than a first predetermined threshold, and determines whether the field signal is greater than a second predetermined threshold. If the monitoring signal is greater than the first predetermined threshold and / or the field signal is greater than the second predetermined threshold, an alarm signal is generated, and the alarm signal, together with the operation signal, is transmitted to the human-machine interaction module via the switch according to the predetermined communication protocol.

[0009] Preferably, the control platform communicates with the external ship management module (112) according to the predetermined communication protocol and transmits the operation signal to the ship management module.

[0010] Preferably, the predetermined modes of the human-machine interaction module include at least one of the following: operating condition overview mode, parameter setting mode, alarm setting mode, historical curve mode, and fault diagnosis mode.

[0011] Preferably, the human-machine interaction module stores the alarm signals and the operation signals, and automatically archives the stored alarm signals and the operation signals according to a predefined data organization structure.

[0012] Preferably, the predefined data organization structure includes: a data organization structure in chronological order and a data organization structure based on user-defined priorities.

[0013] The technical solution of this utility model achieves the following technical effects: The control system for the ship's intermediate-pressure shaft generator achieves significant performance improvements and enhanced operational convenience. Upgrading the control processor unit to an S7-1500 PLC not only improves data processing capabilities but also increases storage capacity, ensuring system stability and reliability. The human-machine interface unit using a TP900 or TP1200 screen provides a more intuitive user experience and optimizes information display. Switching to the Modbus TCP communication protocol enhances communication efficiency and data synchronization capabilities with external devices, while also improving communication security and reliability. The upgraded system, after system integration testing, ensures compatibility between all components and stable system operation, providing a more efficient and safer control solution for the ship's electrical system, significantly improving the efficiency and safety of ship operations. Attached Figure Description

[0014] The accompanying drawings, which are included to provide a further understanding of the present invention and form part of this application, illustrate exemplary embodiments of the present invention and, together with the description thereof, serve to explain the present invention and do not constitute an undue limitation thereof. In the drawings:

[0015] Figure 1 This is a schematic block diagram illustrating a control system for a generator driven by a ship's intermediate pressure shaft according to an embodiment of the present invention.

[0016] List of reference numerals in the attached diagram:

[0017] 102: Control platform;

[0018] 104: Human-computer interaction module;

[0019] 106: Monitoring module;

[0020] 108: Communication program module;

[0021] 110: PN Router Switch

[0022] 112: Ship Management Module Detailed Implementation

[0023] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the protection scope of the present invention.

[0024] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this utility model are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the utility model described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0025] To facilitate understanding, we will now briefly introduce the components used in the control system of the ship's intermediate-pressure shaft generator according to this utility model, as well as their example models and functions:

[0026] The S7-1500 PLC is a programmable logic controller (PLC) from Siemens. It's part of the SIMATIC S7 series and is used to perform control tasks in industrial automation systems. Compared to previous series like the S7-300 and S7-400, the S7-1500 series offers more powerful processing capabilities, faster response times, higher integration, and better energy efficiency. The S7-1500 PLC features include: High-performance processor: Utilizes a faster processor to handle complex control algorithms and large amounts of data. Integrated communication: Supports multiple communication protocols, such as Profinet and Profibus, simplifying network configuration and data exchange. High reliability and safety: Features improved fault diagnosis capabilities and enhanced safety features to ensure stable operation in industrial environments. Modular design: Modules such as input / output modules, communication modules, and power supply modules can be added or removed as needed, providing flexible configuration. Advanced programming tools: Utilizes TIA Portal software for programming and configuration, providing a powerful programming environment and online diagnostic capabilities. The S7-1500 PLC is commonly used in various industrial applications, such as production automation, process control, motion control, and safety control, and is an indispensable part of modern factory automation.

[0027] ET 200MP: Developed by Siemens, ET 200MP is a distributed I / O system part of PROFINET technology used to connect SIMATIC S7-1500 PLCs or other controllers. Representing modularity and high performance, ET 200MP allows for flexible and efficient configuration of input / output (I / O) modules in industrial automation environments to collect and control data from field devices. Features of ET 200MP include: 1. Modular Design: The ET 200MP system consists of various functional modules, including digital input (DI), digital output (DO), analog input (AI), and analog output (AO) modules, which users can select and combine according to field requirements. 2. High-Performance Communication: Enables high-speed communication via PROFINET, suitable for applications requiring rapid response, such as motion control and process control. 3. Integrated Safety Functions: Supports PROFIsafe, enabling safety and standard automation within the same system without additional hardware. 4. Diagnostic Functions: Provides detailed diagnostic information to help quickly locate and resolve problems. 5. Flexible Installation Options: It can be installed in a control cabinet or directly on the machine, increasing installation flexibility. 6. Software Configuration: Configuration and programming are performed via SIMATIC TIA Portal software, simplifying engineering design and maintenance. A key component of the ET 200MP system is its remote I / O station, which can remotely connect to the controller and transmit data to the controller via PROFINET, enabling remote control. Compared to other distributed I / O systems such as the ET 200M, the ET 200MP offers higher performance and flexibility. For example, in the upgrade of the control system for the marine intermediate shaft generator according to this invention, the ET200M module is replaced with the ET200MP or ET200SP module to accommodate the higher performance and requirements of the S7-1500 PLC, and to provide the system with more advanced communication capabilities and higher reliability.

[0028] TP900 and TP1200: These are Human Machine Interface (HMI) devices provided by Siemens, belonging to the SIMATIC HMI series. These devices are typically used in industrial automation environments, acting as a bridge between operators and control systems, allowing operators to monitor and control industrial processes. Specifically: 1. TP900 Comfort: This is a touchscreen panel providing a high-resolution display, suitable for displaying complex process diagrams, process values, and alarms. It supports multilingual displays, has powerful visualization capabilities, and can be integrated into Siemens' Totally Integrated Automation (TIA) concept, configured and programmed through the TIA Portal. The TP900 Comfort also supports advanced functions such as data logging, recipe management, trend charts, and recipes. 2. TP1200 Comfort: This is a larger-screen version of the TP900, typically offering higher resolution and a larger display area. It boasts more advanced HMI features, such as web server functionality for remote viewing of the panel, and more powerful data processing and visualization options. The TP1200 Comfort also supports configuration and programming via the TIA Portal. Common features of the TP900 and TP1200 Comfort include: - Touchscreen operation: Users can operate intuitively via the touchscreen without the need for an additional keyboard or mouse. - Integrated communication: Supports multiple communication protocols, such as PROFINET and OPC UA, enabling communication with controllers (such as S7-1500 PLCs) and other devices. - Advanced functions: Provides advanced HMI functions such as data logging, recipe management, trend charts, and recipes, enhancing operator control. - Flexible design: Can be installed in a control cabinet or directly on the machine, increasing installation flexibility. For example, in the upgrade of the control system for the marine intermediate-pressure shaft generator of this invention, the use of the TP900 (or TP1200) is based on the need for a larger operating screen to provide operators with a better visualization and operating experience, which is an important improvement in the control system of the marine intermediate-pressure shaft generator of this invention.

[0029] TIA Portal V19 is a version of Siemens' Totally Integrated Automation (TIA) engineering design software, with V19 representing the version number. TIA Portal is an integrated engineering platform used for the unified design, configuration, and commissioning of Siemens automation equipment, including SIMATIC S7 series PLCs, HMIs, and drive systems. Key features include: 1. Unified engineering design environment: TIA Portal provides a unified platform for simultaneous programming, configuration, commissioning, and diagnostics of automation equipment, simplifying the entire engineering design process. 2. Powerful programming capabilities: Supports STEP 7 Professional, suitable for programming S7-1500 PLCs, and offers multiple programming languages ​​(such as STL, LAD, FBD, SCL, and GRAPH). 3. Advanced HMI and visualization tools: Through WinCC, advanced graphical user interfaces can be created, enabling visualized monitoring of industrial processes. 4. Integrated drive system configuration: Supports SIMATIC Drive Technology for configuring and commissioning Siemens drive systems, including frequency converters and servo drives. 5. Unified project management: Allows management of all automation equipment within a single project, achieving standardization and consistency. 6. Advanced diagnostic and maintenance tools: Provides powerful commissioning and diagnostic functions, enabling rapid problem location and resolution, improving maintenance efficiency. 7. Support for multiple communication protocols: Supports PROFINET, PROFIBUS, OPC UA, etc., enabling seamless communication between devices. Compared to previous versions, TIA Portal V19 offers more powerful functions, more efficient tools, and more stable operating performance to meet the needs of modern industrial automation. For example, in the upgrade of the control system for the marine intermediate shaft generator described in this utility model, the upgrade from an earlier version (such as TIA Portal V12) to TIA Portal V19 is to utilize the more advanced functions of the S7-1500 PLC, including more powerful processing capabilities and more advanced communication protocols (such as Modbus TCP), as well as to match the latest hardware modules (such as ET 200MP). In addition, TIA Portal V19 may include enhanced security features, improved energy management, and broader device and protocol support, which will help further improve the performance and reliability of automation systems.

[0030] Starterdriver V19 is a software tool developed by Siemens for configuring, commissioning, and monitoring SIMATIC drive systems. More precisely, it's part of SIMATIC Drive Manager and a component of the TIA Portal software package. Starterdriver software is specifically designed for the parameterization of drives and motor controllers, supporting various drive products such as Siemens' SINAMICS series frequency converters and servo drives. Version 19 of Starterdriver may include the following features: 1. Drive parameterization: Allows users to configure drive parameters, such as control mode, speed, torque, and position, graphically to meet specific process requirements. 2. Communication configuration: Supports communication configuration with automation equipment such as S7-1500 PLCs, including protocols such as PROFIdrive and Modbus TCP, ensuring data exchange between the drive and the control system. 3. Monitoring and diagnostics: Provides real-time drive status monitoring and fault diagnosis functions to help users quickly identify and resolve problems. 4. Template and library support: Allows for rapid configuration using predefined templates and libraries, reducing engineering design time. 5. Version Compatibility: This may include compatibility with earlier versions of drive system parameters, as well as support for the latest hardware, such as SINAMICS G120 inverters or drives. 6. Safety Functions: This may include enhanced support for safety-related drive functions, such as Safe Torque Off (STO). For example, in the upgrade of the control system for the marine turbine generator on the pressure shaft of this invention, Starterdriver V19 is used for drive configuration and commissioning, particularly for the communication configuration between the S7-1500 PLC and SH150. This facilitates data exchange between the drive and the control system, improving the performance and reliability of the control system. For instance, configuring the correct data length and communication protocol in Starter is crucial for ensuring accurate data transmission between the control system and the drive system. In this upgrade case, Starterdriver V19 is used to upgrade the data transmission configuration from an incorrect 32 / 32 bytes to a more reasonable 25 / 20 bytes to comply with the requirements of the new Modbus TCP communication protocol. Furthermore, it is used to reconfigure communication with the SINAMICS DC MASTER and other drives to ensure data real-time performance and integrity, thereby improving the overall system performance.

[0031] Modbus RTU (Remote Terminal Unit) communication program: This is a software program based on the Modbus protocol used for data exchange between devices in industrial automation environments. Modbus RTU is a serial communication mode of the Modbus protocol, transmitting data between devices via a serial bus (such as RS-485). Its features include: 1. Data format: Modbus RTU uses 16-bit registers as its data format, allowing devices to read and write data at fixed addresses, making data reading and writing simpler and more reliable. 2. Verification method: Modbus RTU uses CRC (Cyclic Redundancy Check) as its data verification method, effectively detecting errors during transmission. 3. Communication medium: Typically, communication is conducted via an RS-485 serial bus. This bus provides long communication distances and strong anti-interference capabilities, making it suitable for data transmission in industrial environments. 4. Master-slave structure: Modbus RTU communication programs are typically based on a master-slave structure, with one device acting as the master and other devices as slaves. The master sends commands, and the slaves respond to the commands, enabling data reading and writing. 5. Real-time Performance and Reliability: Through reasonable communication program design, Modbus RTU can achieve high real-time performance and reliability, which is crucial for industrial processes requiring real-time monitoring and control. For example, in the upgrade of the control system for the marine intermediate-pressure shaft generator of this invention, the Modbus RTU communication program was used to redevelop data communication between the PLC and the S7-1500 PLC, as well as between the ET200MP module and the external VMS (Vessel Management System). This is because Modbus RTU is widely used in industrial automation systems to realize communication between the PLC and various field devices, including sensors, actuators, and drives. Furthermore, to further improve the real-time performance and efficiency of communication, for example, in the upgrade of the control system for the marine intermediate-pressure shaft generator of this invention, Modbus RTU communication can also be upgraded to Modbus TCP. Modbus TCP is a Modbus communication mode based on Ethernet. It retains the command and data format of Modbus RTU but uses the faster and more reliable Ethernet as the communication medium, which can significantly improve the speed and stability of data transmission. Upgrading from Modbus RTU to Modbus TCP during an upgrade means that the communication program needs to be modified accordingly to adapt to the characteristics and requirements of Ethernet communication. This may include configuring the communication ports, packet encapsulation and decapsulation, and adjusting error handling strategies. By implementing the Modbus TCP communication program, the communication efficiency and data transmission quality of the entire system can be improved, thereby further enhancing the performance and reliability of the control system.

[0032] CU 320: Developed by Siemens, this control unit is primarily used in SINAMICS series frequency converters and drive systems, especially the SINAMICS G120 and SINAMICS S120 series. The CU 320 control unit is responsible for the control, regulation, and monitoring of the frequency converter, and is its core component. It can process motor control algorithms, achieving precise control of motor speed, torque, and position. Features and functions of the CU 320 include: 1. Motor Control: Provides multiple control modes such as PID control, vector control, and servo control to meet different motor control needs. 2. Drive Configuration: Allows users to configure drive parameters via software, such as power supply, motor type, and control mode. 3. Real-time Monitoring: Enables real-time monitoring of the drive's status, including motor speed, current, voltage, and temperature, to ensure normal drive operation. 4. Communication Interface: Provides multiple communication interfaces such as PROFIdrive, CANopen, and USS / DP, allowing the drive to exchange data with PLCs or other automation equipment. 5. Integrated Safety Functions: Supports safety functions such as Safe Torque Off (STO), which can protect the motor and drive system in the event of a fault, reducing the risk of accidents. 6. High Integration: The inverter's control, regulation, monitoring, and communication functions are highly integrated into a single module, simplifying system design and installation. For example, in the upgrade of the control system for the marine turbine generator in this invention, the CU320 was used to redevelop the communication program between the inverter and the S7-1500 PLC and SH150. This typically involves setting drive parameters, transmitting and receiving data, and monitoring drive status. Since the CU320 control unit is responsible for the core control and communication functions within the inverter, the redevelopment of the communication program with the S7-1500 PLC is crucial to ensuring the efficiency and accuracy of data exchange between the inverter and the control system. In the context of an upgrade, it may be necessary to adjust the communication program to accommodate the more advanced functions and communication protocols of the S7-1500 PLC, such as Modbus TCP. In addition, the CU320 control unit may require further optimization or upgrades to ensure it fully performs its role in the upgraded marine shaft-driven generator control system. These upgrades may include improving data processing speed, enhancing anti-interference capabilities, and adding communication protocol support. These improvements will help further enhance the overall system performance and reliability, ensuring the efficient and safe operation of the marine shaft-driven generator.

[0033] DCM (Drive Communication Module): This communication program is specifically designed for communication between Siemens SINAMICS drive systems and external control devices, such as PLCs (Programmable Logic Controllers). In the context of marine shaft-driven generator control systems, the DCM communication program ensures effective communication between the S7-1500 PLC and the SINAMICS drive system, including the CU320 control unit and other possible drive units. Key features of the DCM communication program include: 1. Protocol Support: The DCM communication program supports multiple communication protocols, such as PROFIdrive, PROFINET, and Modbus TCP, enabling the drive system to exchange data with different types of control devices. 2. Data Exchange: The program handles real-time data exchange between the drive system and control devices, including but not limited to drive status information, control commands, and fault data. 3. Configuration and Parameterization: Allows users to configure and parameterize the drive system through a PLC or HMI (Human Machine Interface) device, setting parameters such as drive control mode, speed, and torque. 4. Fault Diagnosis and Handling: It can monitor the operating status of the drive system in real time, diagnose faults, and provide corresponding error handling strategies to help operators or engineers quickly locate and resolve problems. 5. Communication Optimization: Redeveloping the DCM communication program may involve optimizing communication parameters, such as packet size, communication rate, and error checking, to improve real-time performance and reliability. For example, in the upgrade of the control system for the ship's turbine generator, from an earlier S7-300 PLC configuration to an S7-1500 PLC, redeveloping the DCM communication program was necessary. This is because the S7-1500 PLC differs significantly from its predecessor, the S7-300, in hardware performance, software platform (such as TIA Portal V19), and communication protocols (such as upgrading from Modbus RTU to Modbus TCP). Redeveloping the DCM communication program ensures it fully utilizes the advanced features of the S7-1500 PLC and establishes compatibility with the new hardware and communication protocols. For instance, an incorrect configuration of a 32 / 32-byte data length between the S7-300 PLC and the CU320 may have limited communication efficiency. After upgrading to the S7-1500 PLC, the new DCM communication program is configured with a maximum data length of 25 / 20 bytes. This is likely because the S7-1500 PLC has stronger data processing capabilities and a more optimized communication protocol, allowing smaller data packets to provide sufficient real-time performance and reliability while reducing communication latency and errors. Therefore, the redevelopment of the DCM communication program is a crucial part of the upgrade process, essential for ensuring the normal operation of the upgraded ship's intermediate-pressure shaft generator control system and improving its overall performance.By optimizing the communication program, the system can better coordinate the functions of various devices, improve control accuracy, and reduce the failure rate, thereby achieving more efficient and stable operation of the ship's shaft-driven generator.

[0034] SH150: A main control unit in a marine medium-voltage motor drive control system manufactured by Siemens. It is primarily used to control and monitor medium-voltage (MV) motors on ships, especially in electric propulsion systems. The SH150 is part of the SINAMICS series of drives and is designed to meet the special requirements of the marine environment, such as vibration resistance, shock resistance, and salt spray corrosion resistance. Features and functions of the SH150 include: 1. Motor Control: The SH150 can control various types of medium-voltage motors, including asynchronous and synchronous motors. It provides multiple control modes, such as vector control and direct torque control, enabling precise control of motor speed, torque, position, and direction. 2. Communication Interface: The SH150 supports multiple communication protocols, such as PROFIdrive, PROFINET, and Modbus TCP, allowing data exchange with other automation equipment (such as PLCs) for remote monitoring and control. 3. Fault Diagnosis and Protection: The SH150 can monitor the operating status of the motor and drive system in real time, diagnose potential faults, and provide corresponding protection measures, such as overcurrent, overvoltage, and overheat protection. 4. Human-Machine Interface: The SH150 provides a user interface that allows operators to view motor status, parameter settings, and fault information for operation and maintenance. 5. Safety Functions: Supports safety-related functions such as Safe Torque Off (STO), which can quickly cut off the motor's drive power in emergencies to protect personnel and equipment. 6. Energy Management: The SH150 also features energy management capabilities to optimize motor energy consumption, reduce energy waste, and improve energy efficiency. For example, in the control system of the generator driven by the turbine shaft in this invention, the communication program between the SH150 and the S7-1500 PLC needs to be redeveloped. This is because the old S7-300 PLC used the Modbus RTU communication protocol with the SH150, while the new S7-1500 PLC will use the more modern Modbus TCP protocol for communication. This requires redesigning and reprogramming the existing communication program to ensure efficient and reliable data transmission between the SH150 and the new PLC. Furthermore, due to hardware upgrades, the new SH150 may possess greater processing power and more functions. Therefore, these hardware changes must be taken into account when redeveloping the communication program to fully utilize the SH150's potential and improve the overall system performance. The redeveloped communication program will help ensure more precise motor control and more stable communication on the new hardware platform, thereby achieving more efficient operation of the ship's electric propulsion system.

[0035] Figure 1 This is a schematic block diagram illustrating a control system for a ship's intermediate-pressure shaft generator according to an embodiment of the present invention. Although Figure 1 Although not shown, it is clear that the intermediate-pressure shaft generator is located between the main engine and the propeller, and is mounted on the ship's main shaft, with the rotor of the intermediate-pressure shaft generator being coaxially and rigidly connected to the main shaft. The control system includes: a monitoring module 106, electrically connected to the intermediate-pressure shaft-driven generator, which monitors the operating status of the generator and collects data, and generates monitoring signals based on the data; a control platform 102, which communicates with the monitoring module 106 via a PN ROUTER switch 110 according to a predetermined communication protocol to receive monitoring signals and processes the monitoring signals to generate operating signals; and a human-machine interface module 104, which communicates with the control platform 102 via the PN ROUTER switch 110 according to a predetermined communication protocol to receive operating signals, displays the operating signals to the user in a predetermined mode, and receives control commands from the user. The human-machine interface module 104 transmits control commands to the control platform 102 via the PN ROUTER switch 110 according to a predetermined communication protocol. The control platform 102 generates control signals based on the control commands and transmits the control signals to the monitoring module 106 via the PN ROUTER switch 110 according to a predetermined communication protocol. The monitoring module 106 controls the intermediate-pressure shaft-driven generator based on the control signals.

[0036] Specifically, the monitoring module 106 may include the control unit SH150 from the marine medium-voltage motor drive control system manufactured by Siemens. It is primarily used to control and monitor medium-voltage (MV) motors on ships, especially in electric propulsion systems. For example, the monitoring signals generated by the control unit SH150 may include signals indicating the operating status of the cooling water circulation system of the medium-voltage shaft-driven generator. SH150 is part of the SINAMICS series of drives and is designed to meet the special requirements of marine environments, such as vibration resistance, shock resistance, and salt spray corrosion resistance. The features and functions of SH150 include: 1. Motor control: SH150 can control various types of medium-voltage motors, including asynchronous motors and synchronous motors. It provides multiple control modes, such as vector control and direct torque control, enabling precise control of motor speed, torque, position, and direction. 2. Communication interface: SH150 supports multiple communication protocols, such as PROFIdrive, PROFINET, and Modbus TCP, through which data can be exchanged with other automation equipment (such as PLCs) to achieve remote monitoring and control. 3. Fault Diagnosis and Protection: The SH150 can monitor the operating status of the motor and drive system in real time, diagnose potential faults, and provide corresponding protection measures, such as overcurrent, overvoltage, and overheat protection. 4. Human-Machine Interface: The SH150 provides a user interface that allows operators to view motor status, parameter settings, and fault information for operation and maintenance. 5. Safety Functions: Supports safety-related functions, such as Safe Torque Off (STO), which can quickly cut off the motor drive power in emergencies to protect personnel and equipment. 6. Energy Management: The SH150 also features energy management capabilities, optimizing motor energy consumption, reducing energy waste, and improving energy efficiency. For example, in the control system of the generator driven by the turbine shaft in the ship of this invention, the communication program between the generator and the S7-1500 PLC needs to be redeveloped. This is because the older S7-300 PLC used the Modbus RTU communication protocol with the SH150, while the new S7-1500 PLC will use the more modern Modbus TCP protocol. This necessitates redesigning and reprogramming the existing communication program to ensure efficient and reliable data transmission between the SH150 and the new PLC. Furthermore, due to the hardware upgrade, the new SH150 may have greater processing power and more functions. Therefore, these hardware changes must be considered when redeveloping the communication program to fully utilize the SH150's potential and improve the overall system performance. The redeveloped communication program will help ensure more precise motor control and more stable communication on the new hardware platform, thereby achieving more efficient operation of the marine electric propulsion system.

[0037] Specifically, the control platform 102 may include a Siemens S7-1500 PLC (Programmable Logic Controller, or PLC for short) and optionally a Siemens-developed distributed I / O system ET 200MP. For example, the S7-1500 PLC may be considered as the main control unit, and the ET 200MP may be considered as the slave control unit. The slave control unit receives field signals sensed by sensors (e.g., field signals sensed by sensors include signals indicating the temperature of the generator on the intermediate-pressure shaft) and provides the field signals to the main control unit. The main control unit receives the monitoring signals from the monitoring module 106 and the field signals from the slave control unit, and processes the monitoring signals and field signals to generate operating signals. For example, the main control unit may receive the monitoring signals and field signals, determine whether the monitoring signals are greater than a first predetermined threshold, and determine whether the field signals are greater than a second predetermined threshold. If the monitoring signals are greater than the first predetermined threshold and / or the field signals are greater than the second predetermined threshold, an alarm signal is generated, and the alarm signal, along with the operating signal, is transmitted to the human-machine interface module via a switch according to a predetermined communication protocol. The S7-1500 PLC is part of the SIMATIC S7 series, used to perform control tasks in industrial automation systems. Compared to previous series such as the S7-300 and S7-400, the S7-1500 series PLC offers more powerful processing capabilities, faster response times, higher integration, and better energy efficiency. The S7-1500 PLC features include: High-performance processor: Utilizing a faster processor, it can handle complex control algorithms and large amounts of data. Integrated communication: Supports multiple communication protocols, such as Profinet and Profibus, simplifying network configuration and data exchange. High reliability and safety: Features improved fault diagnosis capabilities and enhanced safety features, ensuring stable operation in industrial environments. Modular design: Modules such as input / output modules, communication modules, and power supply modules can be added or removed as needed, providing flexible configuration. Advanced programming tools: Programming and configuration are performed using TIA Portal software, providing a powerful programming environment and online diagnostic capabilities. The S7-1500 PLC is commonly used in various industrial applications, such as production automation, process control, motion control, and safety control, and is an indispensable part of modern factory automation. The ET 200MP, part of PROFINET technology, is used to connect to the SIMATIC S7-1500 PLC or other controllers. The ET200MP represents modularity and high performance, allowing for flexible and efficient configuration of input / output (I / O) modules in industrial automation environments to collect and control data from field devices.The ET 200MP system features include: 1. Modular design: Composed of various functional modules, including digital input (DI), digital output (DO), analog input (AI), and analog output (AO) modules, allowing users to select and combine them according to site requirements. 2. High-performance communication: Enables high-speed communication via PROFINET, suitable for applications requiring rapid response, such as motion control and process control. 3. Integrated safety functions: Supports PROFIsafe, enabling safety and standard automation within the same system without additional hardware. 4. Diagnostic functions: Provides detailed diagnostic information to help quickly locate and resolve problems. 5. Flexible installation options: Can be installed in a control cabinet or directly on the machine, increasing installation flexibility. 6. Software configuration: Simplified engineering design and maintenance through SIMATIC TIA Portal software for configuration and programming. A key component of the ET 200MP system is its remote I / O station, which can remotely connect to the controller and transmit data to the controller via PROFINET, enabling remote control. Compared to other distributed I / O systems such as the ET 200M, the ET 200MP offers higher performance and flexibility. For example, in the upgrade of the control system for the marine intermediate-pressure shaft generator according to this invention, the ET200M module is replaced with the ET200MP or ET200SP module to accommodate the higher performance and requirements of the S7-1500 PLC, and to provide the system with more advanced communication capabilities and higher reliability. For instance, the ET200MP and ET200SP can receive field signals sensed by sensors (e.g., field signals sensed by sensors may include signals indicating the temperature of the intermediate-pressure shaft generator) and provide these field signals to the S7-1500 PLC.

[0038] Specifically, the human-machine interface module 104 may include Siemens' TP900 and TP1200 human-machine interface (HMI) devices, belonging to the SIMATIC HMI series. These devices are typically used in industrial automation environments as a bridge between operators and control systems, allowing operators to monitor and control industrial processes. Specifically: 1. TP900 Comfort: This is a touchscreen panel providing a high-resolution display suitable for displaying complex process screens, process values, and alarms. It supports multilingual displays, has powerful visualization capabilities, and can be integrated into Siemens' Totally Integrated Automation (TIA) concept, configured and programmed through the TIA Portal. The TP900 Comfort also supports advanced functions such as data logging, recipe management, trend charts, and recipes. 2. TP1200 Comfort: This is a larger-screen version of the TP900, typically offering higher resolution and a larger display area. It has more advanced HMI functions, such as web server functionality for remote viewing of the panel screen, and more powerful data processing and visualization options. The TP1200 Comfort also supports configuration and programming via the TIA Portal. Common features of the TP900 and TP1200 Comfort include: - Touchscreen operation: Users can operate intuitively via the touchscreen without the need for an additional keyboard or mouse. - Integrated communication: Supports multiple communication protocols, such as PROFINET and OPCUA, enabling communication with controllers (such as S7-1500 PLCs) and other devices. - Advanced functions: Provides advanced HMI functions such as data logging, recipe management, trend charts, and recipes, enhancing operator control. - Flexible design: Can be installed in a control cabinet or directly on the machine, increasing installation flexibility. For example, in the upgrade of the control system for the marine intermediate-pressure shaft generator of this invention, the use of the TP900 (or TP1200) is based on the need for a larger operating screen to provide operators with a better visualization and operating experience, which is an important improvement in the control system of the marine intermediate-pressure shaft generator of this invention. The human-machine interface module can display operating signals to the user according to predetermined modes, which include at least one of the following: operating condition overview mode, parameter setting mode, alarm setting mode, historical curve mode, and fault diagnosis mode. Furthermore, the human-machine interface module can store alarm signals and operating signals, and automatically archive the stored alarm signals and operating signals according to a predefined data organization structure. For example, the predefined data organization structure may include: a data organization structure in chronological order, and a data organization structure according to user-defined priorities.

[0039] In addition, at least one of the monitoring module 106, control platform 102, and human-machine interface module 104 is communicatively connected to the communication program module 108 via the PNROUTER switch 110 according to a predetermined communication protocol. The communication program module 108 may include a DCM (Drive Communication Module), which is a software program specifically designed for communication between Siemens SINAMICS drive systems and external control devices, such as PLCs (Programmable Logic Controllers). In the context of a marine shaft generator control system, the DCM communication program ensures effective communication between the S7-1500 PLC and the SINAMICS drive system, including the CU320 control unit and other possible drive units. Key features of the DCM communication program: 1. Protocol support: The DCM communication program supports multiple communication protocols, such as PROFIdrive, PROFINET, ModbusTCP, etc., enabling the drive system to exchange data with different types of control devices. 2. Data exchange: The program is responsible for real-time data exchange between the drive system and the control device, including but not limited to drive status information, control commands, fault data, etc. 3. Configuration and Parameterization: Allows users to configure and parameterize the drive system via PLC or HMI (Human-Machine Interface) devices, setting parameters such as drive control mode, speed, and torque. 4. Fault Diagnosis and Handling: Enables real-time monitoring of the drive system's operating status, diagnoses faults, and provides corresponding error handling strategies to help operators or engineers quickly locate and resolve problems. 5. Communication Optimization: Redeveloping the DCM communication program may include optimizing communication parameters such as data packet size, communication rate, and error checking to improve communication real-time performance and reliability. For example, in the upgrade of the control system for the marine intermediate pressure shaft generator of this invention, from the earlier S7-300 PLC configuration to the S7-1500 PLC, the redevelopment of the DCM communication program is necessary. This is because the S7-1500 PLC differs significantly from its predecessor, the S7-300, in terms of hardware performance, software platform (such as TIA Portal V19), and communication protocol (such as upgrading from Modbus RTU to Modbus TCP). The DCM communication program was redeveloped to ensure it could fully utilize the advanced features of the S7-1500 PLC and establish compatibility with new hardware and communication protocols. For example, a misconfiguration of 32 / 32-byte data lengths between the S7-300 PLC and the CU320 could limit communication efficiency.After upgrading to the S7-1500 PLC, the new DCM communication program is configured with a maximum data length of 25 / 20 bytes. This is likely because the S7-1500 PLC has stronger data processing capabilities and a more optimized communication protocol, allowing smaller data packets to provide sufficient real-time performance and reliability while reducing communication latency and errors. Therefore, the redevelopment of the DCM communication program is a crucial part of the upgrade, essential for ensuring the normal operation of the upgraded ship's intermediate-pressure shaft-driven generator control system and improving its overall performance. By optimizing the communication program, the system can better coordinate the functions of various devices, improve control accuracy, reduce failure rates, and thus achieve more efficient and stable operation of the ship's shaft-driven generator.

[0040] Furthermore, the control platform 102 can also communicate with the external ship management module 112 according to a predetermined communication protocol. The predetermined communication protocol may include Modbus TCP, an Ethernet-based Modbus communication mode that retains the command and data format of Modbus RTU but uses the faster and more reliable Ethernet as the communication medium, significantly improving data transmission speed and stability. Upgrading from Modbus RTU to Modbus TCP requires corresponding modifications to the communication program to adapt to the characteristics and requirements of Ethernet communication. This may include configuring the communication ports, packet encapsulation and decapsulation, and adjusting error handling strategies. Implementing the Modbus TCP communication program improves the overall system's communication efficiency and data transmission quality, thereby further enhancing the performance and reliability of the control system.

[0041] Furthermore, the communication parameters and data format of the control platform 102 can be configured using TIA Portal V19 and / or Starterdriver V19 software to ensure that the communication protocol of the control platform 102 conforms to the predetermined communication protocol. TIA Portal V19: This is one version of the Totally Integrated Automation (TIA) engineering design software developed by Siemens. V19 represents the software version number. TIA Portal is an integrated engineering platform used for the unified design, configuration, and debugging of Siemens automation equipment, including SIMATIC S7 series PLCs, HMIs, and drive systems. Key features include: 1. Unified engineering design environment: TIA Portal provides a unified platform that allows for simultaneous programming, configuration, debugging, and diagnostics of automation equipment, simplifying the entire engineering design process. 2. Powerful programming capabilities: Supports STEP 7 Professional, suitable for programming S7-1500 PLCs, and provides multiple programming languages ​​(such as STL, LAD, FBD, SCL, and GRAPH). 3. Advanced HMI and visualization tools: WinCC enables the creation of advanced graphical user interfaces for visualized monitoring of industrial processes. 4. Integrated drive system configuration: Supports SIMATICDrive Technology for configuring and commissioning Siemens drive systems, including frequency converters and servo drives. 5. Unified project management: Allows management of all automation equipment within a single project, achieving standardization and consistency. 6. Advanced diagnostic and maintenance tools: Provides powerful commissioning and diagnostic functions for rapid problem location and resolution, improving maintenance efficiency. 7. Support for multiple communication protocols: Supports seamless communication between devices, such as PROFINET, PROFIBUS, and OPC UA. Compared to previous versions, TIA Portal V19 offers more powerful features, more efficient tools, and more stable operation to meet the demands of modern industrial automation. For example, in the upgrade of the control system for the ship's turbine generator on the mid-shaft, as described in this invention, the upgrade from an earlier version (such as TIA Portal V12) to TIA Portal V19 is to take advantage of the more advanced features of the S7-1500 PLC, including its more powerful processing capabilities and more advanced communication protocols (such as ModbusTCP), as well as to match the latest hardware modules (such as ET 200MP). Furthermore, TIA Portal V19 may also include enhanced safety features, improved energy management, and broader device and protocol support, which will help further improve the performance and reliability of the automation system.Starterdriver V19 is a software tool developed by Siemens for configuring, commissioning, and monitoring SIMATIC drive systems. More precisely, it's part of SIMATIC Drive Manager and a component of the TIAPortal software package. Starterdriver software is specifically designed for the parameterization of drives and motor controllers, supporting various drive products such as Siemens' SINAMICS series frequency converters and servo drives. Version 19 of Starterdriver may include the following features: 1. Drive parameterization: Allows users to configure drive parameters, such as control mode, speed, torque, and position, graphically to meet specific process requirements. 2. Communication configuration: Supports communication configuration with automation equipment such as S7-1500 PLCs, including protocols such as PROFIdrive and Modbus TCP, ensuring data exchange between the drive and the control system. 3. Monitoring and diagnostics: Provides real-time drive status monitoring and fault diagnosis functions to help users quickly identify and resolve problems. 4. Template and library support: Allows for rapid configuration using predefined templates and libraries, reducing engineering design time. 5. Version Compatibility: This may include compatibility with earlier versions of drive system parameters, as well as support for the latest hardware, such as SINAMICS G120 inverters or drives. 6. Safety Functions: This may include enhanced support for safety-related drive functions, such as Safe Torque Off (STO). For example, in the upgrade of the control system for the marine turbine generator on the pressure shaft of this invention, Starterdriver V19 is used for drive configuration and commissioning, particularly for the communication configuration between the S7-1500 PLC and SH150. This facilitates data exchange between the drive and the control system, improving the performance and reliability of the control system. For instance, configuring the correct data length and communication protocol in Starter is crucial for ensuring accurate data transmission between the control system and the drive system. In this upgrade case, StarterdriverV19 is used to upgrade the data transmission configuration from an incorrect 32 / 32 bytes to a more reasonable 25 / 20 bytes to comply with the requirements of the new Modbus TCP communication protocol. Furthermore, it is used to reconfigure communication with the SINAMICS DC MASTER and other drives to ensure data real-time performance and integrity, thereby improving the overall system performance.

[0042] Furthermore, in the upgrade of the control system for the ship's turbine generator, the PN ROUTER switch can be replaced from the original XC208 device to the MOXA EDS-408A-PN network security switch, thus meeting the increasingly stringent network security requirements of ships. The MOXA EDS-408A-PN is an industrial-grade Ethernet switch specifically designed for industrial automation networks, providing highly reliable data transmission and network connectivity. Manufactured by Moxa, a company specializing in industrial communication solutions, its products are widely used in factory automation, transportation, energy, environmental protection, and other fields requiring rugged network equipment. Key features of the Moxa EDS-408A-PN include: 1. Industrial-grade design: Moxa industrial switches typically feature wide operating temperatures, shock resistance, dust resistance, and corrosion resistance, making them suitable for stable operation in harsh industrial environments. 2. Profinet compatibility: The EDS-408A-PN specifically mentions compatibility with the Profinet protocol, meaning it can be seamlessly integrated into Profinet networks as part of a Profinet device, providing network connectivity and data exchange. 3. Network Security Features: As a secure switch, it may have enhanced network security features such as access control, data encryption, and firewalls to protect the network from unauthorized access and attacks. 4. High Reliability and Redundancy: Industrial switches typically support ring redundancy technologies, such as Turbo Ring, Turbo Chain, or other proprietary technologies from Moxa, ensuring rapid connection restoration and continued data transmission in the event of partial network failure. 5. Management Functions: The Moxa EDS-408A-PN may offer manageable functions, allowing users to configure and monitor the switch's operating status, and perform fault diagnosis and troubleshooting through network management software. 6. Flexible Installation: Industrial switches typically support DIN rail mounting or wall mounting, suitable for various industrial environment types. 7. PoE Support: Some models may also support Power over Ethernet (PoE), providing power to connected devices and simplifying field cabling. 8. High Bandwidth: Provides multiple Gigabit Ethernet ports, supporting high-speed data transmission to meet the bandwidth requirements of modern industrial automation networks. In the control system of a ship's turbine generator, the Moxa EDS-408A-PN network security switch can serve as part of the network infrastructure, connecting system components such as monitoring modules, control platforms, and human-machine interface modules, as well as facilitating communication with external ship management modules. It not only provides data transmission channels but also protects the system from network threats through its network security features, ensuring data integrity and system security.Meanwhile, its high reliability and redundancy design ensure that the control system continues to operate normally even in the event of partial network failure, without affecting the stability and efficiency of the generator driven by the ship's mid-spindle turbine. The Moxa EDS-408A-PN network security switch plays a crucial role in industrial automation networks, especially in environments requiring the processing of large amounts of data, high real-time performance, and stringent security requirements, such as ship power system control and factory automation control. Using such an industrial-grade switch ensures stable network operation, reduces data transmission latency, enhances network anti-interference capabilities, and improves overall system performance and reliability.

[0043] Table 1 below lists the comparison data of various parameters between the S7-300 series and the S7-1500 series.

[0044] Table 1:

[0045]

[0046] As shown in Table 1, the updated control processor unit of the S7-1500 PLC not only improves data processing capabilities but also increases storage capacity, ensuring system stability and reliability. Furthermore, the technical solution of this invention also reduces hardware costs.

[0047] The technical solution of this utility model achieves the following technical effects:

[0048] 1. The control system for the generator on the ship's intermediate shaft will be much more robust than before.

[0049] 2. The efficiency of the control system for the generator driven by the intermediate shaft of the ship has been improved.

[0050] 3. Update all hardware and software to the latest technology.

[0051] 4. Customers can easily obtain spare parts.

[0052] 5. The control system for the generator on the ship's intermediate shaft, provided, reduces hardware costs.

[0053] The above description is merely a preferred embodiment of this utility model and is not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A control system for a medium voltage shaft generator of a marine vessel, said medium voltage shaft generator being arranged between a main engine and a propeller and said medium voltage shaft generator being mounted on a main shaft of said marine vessel, a rotor of said medium voltage shaft generator being co-axially fixed to said main shaft, characterized in that, The control system for the medium-voltage shaft generator of the ship comprises: a monitoring module (106) electrically connected to the medium-voltage shaft generator, which monitors the operating state of the medium-voltage shaft generator and collects data, and generates a monitoring signal based on the data; a control platform (102) communicatively connected to the monitoring module via a switch (110) to receive the monitoring signal according to a predetermined communication protocol, and generates an operating signal based on the monitoring signal; and a human-machine interaction module (104) communicatively connected to the control platform via the switch according to the predetermined communication protocol to receive the operating signal, and displays the operating signal to a user in a predetermined mode, and receives a control instruction of the user, wherein the human-machine interaction module transmits the control instruction to the control platform via the switch according to the predetermined communication protocol, the control platform generates a control signal based on the control instruction and transmits the control signal to the monitoring module, and the monitoring module controls the medium-voltage shaft generator based on the control signal.

2. A control system for a medium voltage shaft generator of a marine vessel according to claim 1, characterized in that, The control platform comprises a master control unit and a slave control unit, the slave control unit receives a field signal sensed by a sensor and provides the field signal to the master control unit, and the master control unit receives the monitoring signal and the field signal, and generates the operating signal based on the monitoring signal and the field signal.

3. A control system for a medium voltage shaft generator of a marine vessel according to claim 2, characterized in that, The field signal sensed by the sensor comprises a signal indicating the temperature of the medium-voltage shaft generator, and the monitoring signal comprises a signal indicating the operating state of a cooling water circulation system of the medium-voltage shaft generator.

4. A control system for a medium voltage shaft generator of a marine vessel according to claim 3, characterized in that, The master control unit receives the monitoring signal and the field signal, determines whether the monitoring signal is greater than a first predetermined threshold value and whether the field signal is greater than a second predetermined threshold value, and generates an alarm signal in the case that the monitoring signal is greater than the first predetermined threshold value and / or the field signal is greater than the second predetermined threshold value, and transmits the alarm signal to the human-machine interaction module via the switch according to the predetermined communication protocol together with the operating signal.

5. The control system of a medium voltage shaft generator for a marine vessel according to any one of claims 1 to 4, characterized in that, The control platform communicates data with an external ship management module (112) according to the predetermined communication protocol, and transmits the operating signal to the ship management module.

6. The control system of a medium voltage shaft generator for a marine vessel according to any one of claims 1 to 4, characterized in that, The predetermined mode of the human-machine interaction module comprises at least one of the following: a working condition overview mode, a parameter setting mode, an alarm setting mode, a historical curve mode, and a fault diagnosis mode.

7. A control system for a medium voltage shaft generator of a marine vessel according to claim 4, characterized in that, The human-machine interaction module stores the alarm signal and the operating signal, and automatically archives the stored alarm signal and operating signal according to a predefined data organization structure.

8. A control system for a medium voltage shaft generator of a marine vessel according to claim 7, characterized in that, The predefined data organization structure comprises a time-sequential data organization structure and a user-defined priority data organization structure.

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