Movable high-power diesel-electric hybrid system comprehensive performance test cabin

Abstract

The utility model discloses a movable high -power diesel -electric hybrid power system comprehensive performance test cabin relates to the comprehensive performance test technical field of diesel -electric hybrid intelligent power unit, including movable square cabin cabin body and cabin body accessory system, and cabin body accessory system includes refrigerating system, fresh air ventilation system, safety protection and harmful gas detection system, movable cooling water system, and cabin body can move to the altitude 5000m height with vehicle, and the refrigerating system that can work in the wide temperature range of -43~55 DEG C is collocated, 40000m 3 / h high -flow fresh air ventilation system, has realized that the high altitude low pressure start -up, heat dissipation performance and power performance test that traditional fixed test equipment is difficult to accomplish, has solved the disparity problem of power unit performance detection under the simulation environment and actual plateau environment, integral type design does not need secondary installation, and the test host is separated / connected in 30 seconds through the track structure and motor test bench, and the positioning accuracy is plus or minus 1mm, and cooperates the standardization interface, and the equipment debugging time is greatly shortened.

Description

Technical Field

[0001] This utility model relates to the field of comprehensive performance testing technology for diesel-electric hybrid intelligent power units, and in particular to a mobile high-power diesel-electric hybrid power system comprehensive performance testing chamber. Background Technology

[0002] As a core power system for high-end equipment, the diesel-electric hybrid intelligent power unit integrates a high-power-density water-cooled diesel engine, an ISG generator, and intelligent control technology. It boasts advantages such as flexible electric drive and a compact, lightweight design, with a rated electric power of 300kW. Its performance testing needs to cover complex operating conditions such as high and low temperature start-up and high-altitude heat dissipation. However, traditional testing relies on fixed test benches or single-environment simulation equipment, which has significant drawbacks: the simulated environment differs greatly from actual high-altitude and humid conditions in terms of air pressure and density, leading to distorted power unit performance data and failing to accurately reflect the operating status under extreme environments.

[0003] Existing technologies also suffer from insufficient mobility. Fixed test benches cannot meet the needs of field and high-altitude testing, and the fixed size and functions of the equipment make it difficult to adapt to the future expansion of testing for high-power power units, resulting in redundant construction. Simultaneously, the level of safety monitoring and automation is low, lacking real-time linkage protection against harmful gases and intelligent multi-parameter control, thus limiting testing efficiency and safety. As power units develop towards higher power and integration, there is an urgent need for a testing platform that combines mobility, full-environment simulation capabilities, and intelligent control to address issues such as poor adaptability to complex environments and low data reliability, thereby meeting the pressing needs of high-end equipment development. Utility Model Content

[0004] To address the shortcomings of existing technologies, this utility model provides a mobile high-power diesel-electric hybrid power system comprehensive performance test chamber, which solves the technical problems of difficulty in conducting on-site performance tests of existing diesel-electric hybrid intelligent power units in complex environments such as high altitudes, large deviations between simulated environment and actual working conditions, and insufficient mobility and safety of test equipment.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A mobile high-power diesel-electric hybrid power system comprehensive performance test chamber, including a mobile container body and auxiliary systems of the body;

[0007] The mobile modular cabin is an insulated cabin with an insulated floor. Its internal dimensions are 6.0m (L) × 4.5m (W) × 4.5m (H), the entrance and exit dimensions are 2.4m × 3.0m (W × H), and the personnel entrance and exit dimensions are 1.0m (W) × 2.0m (H). It can be moved by vehicle to an altitude of 5000m.

[0008] The cabin's auxiliary systems include a refrigeration system, a fresh air exchange system, a safety protection and harmful gas detection system, and a mobile cooling water system.

[0009] Preferred configuration: The refrigeration system operates within a temperature range of -43℃ to 55℃, and the fresh air exchange system has an airflow rate of 40,000 m³ / h. 3 The safety protection and harmful gas detection system has high HC and CO concentration alarm and protection functions. The mobile cooling water system has a cooling water temperature of 32℃ and a water flow rate of 180t / h.

[0010] Preferred options include automated measurement and control systems, data acquisition systems, cooling systems, and infrastructure.

[0011] Automated measurement and control systems include control instruments, cabinets, industrial computers and displays, software, uninterruptible power supplies, audible and visual indicator lights and displays, and emergency stop devices;

[0012] The data acquisition system includes a data acquisition module, a hub box and bracket, thermocouples, sensors, a start / stop device, a throttle actuator and mounting bracket, an exhaust back pressure regulating device, and an intake pressure regulating device;

[0013] The heat dissipation system includes a water cooling system and a circulating air system;

[0014] The infrastructure includes an electric dynamometer and its base, couplings, transition plates, fuel consumption measurement and control devices, engine intake and exhaust systems and outriggers, fuel supply systems, exhaust and smoke extraction systems, lighting systems, driving systems, water system modification components, sewage pipe modification components, high-pressure air pipe modification components, and electrical wiring modification components.

[0015] Preferably, the working chamber of the test chamber has dimensions of 4000mm × 1400mm × 2000mm (D × W × H) and an internal volume of 11.2m³. 3 The external dimensions are designed based on the dimensions of the test bench. The test chamber adopts an integrated design. The equipment can be used after it is installed in place and connected to the power supply. The test host can be separated and connected to the motor test bench through a track structure.

[0016] Compared with the prior art, the present invention has the following beneficial effects:

[0017] 1. The cabin can be moved with the vehicle to an altitude of 5000m, equipped with a refrigeration system capable of operating in a wide temperature range of -43 to 55℃, and a 40000m altitude. 3The high-flow-rate fresh air exchange system enables high-altitude, low-pressure start-up, heat dissipation, and power performance testing, which is difficult to perform with traditional fixed testing equipment. It solves the gap between simulated environment and actual plateau environment power unit performance testing, ensuring that the test data is closer to real working conditions. Through the insulated chamber (heat leakage rate ≤500W / ℃), mobile cooling water system (water temperature 32℃, flow rate 180t / h), and intelligent temperature and humidity control, it can accurately simulate comprehensive environments such as high and low temperatures, humidity and heat, and low air pressure, covering the test requirements of multiple standards such as IEC, MIL, and GB, and meeting the reliability testing needs of products in multiple fields such as electrical and electronic engineering and power units under extreme conditions.

[0018] II. The integrated design eliminates the need for secondary installation. The test host can be separated / connected to the motor test bench within 30 seconds via a track structure, with a positioning accuracy of ±1mm. Standardized interfaces (cable drag chains, quick-connect air hoses) significantly shorten equipment debugging time. The chamber dimensions (4000×1400×2000mm) and adjustable layout are compatible with different power units (existing 300kW and future upgrade models), avoiding redundant construction costs. The automated measurement and control system collects data from 20+ key measurement points (temperature, pressure, power, etc.) in real time with an accuracy of ±0.1%FS, supporting automatic operation under preset conditions and data curve generation. The safety protection system uses high-sensitivity HC / CO sensors (accuracy ±5% / ±2%) to achieve three-level alarm linkage (audible and visual alarm, enhanced fresh air, power cut-off), with a response time ≤5s. Combined with explosion-proof ventilation openings and hydraulically leveling legs, it ensures testing safety and data reliability in hazardous environments such as high altitudes and high temperatures. Attached Figure Description

[0019] The above description is only an overview of the technical solution of this utility model. In order to better understand the technical means of this utility model and to implement it in accordance with the contents of the specification, the preferred embodiments of this utility model are described in detail below with reference to the accompanying drawings.

[0020] Figure 1 This is a schematic diagram of the composition of the test chamber in this utility model. Detailed Implementation

[0021] This application provides a mobile, high-power diesel-electric hybrid power system comprehensive performance test chamber, which effectively solves the technical problems of existing diesel-electric hybrid intelligent power units being difficult to test in complex environments such as high altitudes, having large deviations between simulated environment and actual working conditions, and lacking mobility and safety of test equipment.

[0022] Example

[0023] like Figure 1 As shown, the overall technical solution in this application embodiment is as follows:

[0024] To address the problems existing in the prior art, this utility model provides a mobile high-power diesel-electric hybrid power system comprehensive performance test chamber, mainly composed of a mobile cabin body and auxiliary systems, equipped with automated measurement, data acquisition, heat dissipation systems and infrastructure, to realize performance testing of diesel-electric hybrid intelligent power units in complex environments such as high and low temperatures and high altitudes. The following describes the implementation of each part in detail with reference to the accompanying drawings and specific parameters.

[0025] Cabin structure design:

[0026] Main structure:

[0027] It adopts a combination structure of all-metal frame + heat insulation board. The frame material is Q345B steel, and the surface is sprayed with anti-corrosion coating (thickness ≥80μm).

[0028] The cabin walls and roof have a double-layer insulation structure. The inner layer is a 30mm thick polyurethane foam board (thermal conductivity ≤0.024W / (m·K)), and the outer layer is a 2mm thick galvanized steel plate. The bottom is equipped with an insulated floor (50mm thick glass wool insulation layer + non-slip metal pedal) to ensure that the cabin heat leakage rate is ≤500W / ℃.

[0029] Dimensions:

[0030] Interior dimensions: 6.0m (length) × 4.5m (width) × 4.5m (height), effective volume 121.5m³. 3 It provides sufficient space for the installation and testing of high-power power units (such as a 300kW diesel-electric hybrid module);

[0031] Entrance door: Dimensions 2.4m (width) × 3.0m (height), using an electric lifting sealing door with rubber sealing strips (compression ≥ 5mm) to ensure airtightness in high-altitude, low-pressure environments;

[0032] Personnel entrance / exit: 1.0m (width) × 2.0m (height), equipped with an observation window (double-glazed, 10mm thick) and a safety lock.

[0033] Mobility performance:

[0034] The bottom of the cabin integrates a standard trailer interface (compliant with GB / T25980-2010), which can be towed by heavy trucks to plateaus with an altitude of 5000m. It is equipped with adjustable hydraulic outriggers (stroke ±200mm) to ensure that the cabin levelness is ≤1° during testing.

[0035] Internal layout of the cabin:

[0036] Test area: The central power unit mounting platform adopts a shock-absorbing base (natural frequency ≤5Hz) and is equipped with a track-type sliding bracket to support the rapid positioning of the device under test;

[0037] Operating area: The side is equipped with a control cabinet and industrial computer console, which integrates a display screen, operation buttons and emergency stop device (compliant with GB16754-2008 safety standards);

[0038] Cable routing: Metal cable trays are installed at the top and under the floor to separate strong and weak current cables, and fireproof sealing materials are used to ensure signal transmission stability.

[0039] Refrigeration system:

[0040] It adopts a two-stage compression refrigeration cycle, with a Bitzer CSH6573-150Y compressor, and is equipped with a finned evaporator (heat exchange area ≥50㎡) and a condenser (air-cooled + water-cooled composite type);

[0041] Temperature control range: -43℃~55℃, accuracy ±0.5℃ (high temperature range) / ±1℃ (low temperature range), refrigerant flow is automatically adjusted through PID algorithm;

[0042] Low temperature protection:

[0043] Equipped with an electric heating auxiliary device (power 50kW), it preheats the cabin in high-altitude and low-temperature environments to ensure that the power unit starts at a temperature ≥-40℃;

[0044] The pipeline is insulated with heat tracing tape (maintaining a temperature ≥5℃) to prevent condensate from freezing.

[0045] Fresh air exchange system:

[0046] Core components:

[0047] Main fan: Centrifugal fan (model GDF-400), rated flow 40,000 m³ / h 3 / h, wind pressure ≥1500Pa, equipped with silencer (noise reduction ≥30dB);

[0048] Air filtration: Three-stage filtration (pre-filter G4 + medium-efficiency filter F8 + high-efficiency filter H13), filtration efficiency ≥99.97% (0.3μm particles);

[0049] Airflow organization:

[0050] It adopts a top air supply and bottom air return mode, and is equipped with a deflector (angle adjustable from 15° to 45°) to ensure that the air velocity uniformity in the cabin is ≤0.5m / s;

[0051] High-altitude mode: Automatically adjusts fan speed using a barometric pressure sensor (accuracy ±0.1 kPa) to compensate for the decrease in air density at an altitude of 5000 m (approximately 50% of that at sea level).

[0052] Safety protection and hazardous gas detection system:

[0053] Detection module:

[0054] Gas sensors: HC (range 0~1000ppm, accuracy ±5%), CO (range 0~2000ppm, accuracy ±2%), installed at the top (density lower than air) and bottom (density higher than air) of the chamber;

[0055] Protection mechanism:

[0056] When HC≥500ppm or CO≥300ppm, a three-level alarm is triggered: Level 1: audible and visual alarm (buzzer ≥85dB + red indicator light); Level 2: automatic start of the fresh air system (flow rate increased to 110%); Level 3: power unit power cut-off (response time ≤5s).

[0057] An emergency ventilation opening (0.5m x 0.5m) is provided, equipped with an explosion-proof electric valve that can be manually opened in the event of a power outage.

[0058] Mobile cooling water system:

[0059] Waterway design:

[0060] Water pump: Horizontal centrifugal pump (model ISW150-200), rated flow 180t / h, head 50m, equipped with frequency converter (adjustment accuracy ±1%);

[0061] Temperature control: The cooling water temperature is stabilized at 32℃±2℃ by using a plate heat exchanger (heat exchange area ≥30㎡) and a temperature sensor (accuracy ±0.1℃).

[0062] Piping configuration:

[0063] The pipe is made of 316L stainless steel (3mm wall thickness), and the connection uses quick couplings (leakage rate ≤10%). -9 m 3 / s), equipped with a pressure sensor (range 0~1MPa, accuracy ±0.5%) to monitor water pressure in real time.

[0064] Automated measurement and control systems:

[0065] Hardware configuration:

[0066] Industrial PC: Advantech IPC-610L, equipped with an Intel i7 processor and 16GB of memory, pre-installed with Windows 10 Industrial Edition;

[0067] Control instrument: Siemens S7-1200 PLC, integrating analog input module (accuracy ±0.1%FS) and digital output module;

[0068] Human-machine interface: 15-inch touch screen (1920×1080 resolution), which displays parameters such as temperature, pressure, and power in real time;

[0069] Software features:

[0070] It supports manual / automatic mode switching. In automatic mode, the test parameters can be automatically adjusted according to preset working conditions (such as high altitude start-up and high temperature heat dissipation).

[0071] It has data storage (interval ≤10ms) and curve plotting functions, and the data format is compatible with Excel and MATLAB.

[0072] Data acquisition system:

[0073] Sensor configuration:

[0074] Temperature: Type K thermocouples (accuracy ±1℃) are installed at 20 measuring points, including the power unit cylinder, generator windings, and cooling water inlet and outlet.

[0075] Pressure: Absolute pressure sensor (range 0~100kPa, accuracy ±0.25%FS) is used for high-altitude air pressure monitoring, and differential pressure sensor (range 0~10kPa, accuracy ±0.1%FS) is used for intake pressure regulation;

[0076] Data Acquisition Module:

[0077] It adopts Advantech ADAM-6000 series distributed modules, supports Modbus TCP / IP protocol, data transmission rate ≥100Mbps, and anti-interference capability complies with GB / T17626.2-2018 (electrostatic discharge).

[0078] Cooling system:

[0079] Water cooling system:

[0080] Radiator: Tube-plate structure (copper / aluminum material), heat dissipation area ≥200㎡, equipped with electric ball valve (opening and closing time ≤3s) to control cooling water flow;

[0081] Circulating air system:

[0082] Fan: Axial flow fan (model T35-11), air volume 50,000 m³ / h 3 / h, combined with a fairing to achieve air circulation inside the cabin, ensuring that the surface wind speed of the power unit is ≥2m / s.

[0083] Infrastructure:

[0084] Electric dynamometer:

[0085] Model: CW400 eddy current dynamometer, rated power 400kW, speed range 0~3000rpm, equipped with a high-precision torque sensor (accuracy ±0.1%FS);

[0086] Fuel supply system:

[0087] The fuel tank has a capacity of 500L, and is equipped with a gear pump (flow rate 50L / min) and a fuel filter (filtration accuracy ≤10μm), supporting diesel / biodiesel dual-fuel mode;

[0088] Track structure:

[0089] The test host and the motor test bench are connected by **H-shaped steel rails (model QU80)**. The rails are 6m long and equipped with four sets of rollers (150mm in diameter, with a load capacity of ≥50t), enabling rapid separation / connection within 30 seconds with a positioning accuracy of ±1mm.

[0090] Key performance parameters:

[0091]

[0092] Working principle:

[0093] High-altitude environment testing procedure:

[0094] Transportation to the site: The cabin was transported to the test site at an altitude of 5000m by trailer, and the hydraulic outriggers were activated for leveling.

[0095] Environmental simulation:

[0096] Turn on the cooling system to -20℃, and the fresh air system at 40,000m 3 The system operates at a flow rate of / h, simulating a high-altitude, low-temperature, and low-pressure environment.

[0097] Start the power unit and monitor the starting current, cylinder temperature, and generator output power through the data acquisition system;

[0098] Safety protection: When the CO concentration exceeds 300ppm, the system automatically cuts off the fuel supply and sounds an alarm, and test personnel evacuate through the emergency exit;

[0099] Data processing: The industrial computer automatically generates test reports to compare performance differences between plain and plateau environments (such as startup time extension rate and heat dissipation efficiency reduction).

[0100] High temperature and humidity test:

[0101] The cooling system was set to 55℃, and the humidity control system (electric heating humidification + refrigeration dehumidification) controlled the relative humidity at 85% ± 5%. The insulation performance and heat dissipation capacity of the power unit were tested under high temperature and high humidity conditions. The cooling water system circulated at 32℃ and 180t / h to ensure the temperature of the tested equipment was stable.

[0102] Finally, it should be noted that the above embodiments are merely examples for clearly illustrating the present invention and are not intended to limit the implementation. Those skilled in the art can make other variations or modifications based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations. However, obvious variations or modifications derived therefrom are still within the protection scope of this invention.

Claims

1. A portable high-power diesel-electric hybrid power system comprehensive performance test chamber, characterized in that, Includes the mobile modular container and its ancillary systems; The mobile modular cabin is an insulated cabin with an insulated floor. Its internal dimensions are 6.0m×4.5m×4.5m, the entrance and exit dimensions are 2.4m×3.0m, and the personnel entrance and exit dimensions are 1.0m×2.0m. The cabin's auxiliary systems include a refrigeration system, a fresh air exchange system, a safety protection and harmful gas detection system, and a mobile cooling water system.

2. The portable high-power diesel-electric hybrid power system comprehensive performance test chamber as described in claim 1, characterized in that: The operating temperature range of the refrigeration system is -43℃ to 55℃.

3. The portable high-power diesel-electric hybrid power system comprehensive performance test chamber as described in claim 1, characterized in that: The airflow rate of the fresh air exchange system is 40,000 m³ / h. 3 / h.

4. The mobile high-power diesel-electric hybrid power system comprehensive performance test chamber as described in claim 1, characterized in that: The safety protection and hazardous gas detection system has alarm and protection functions for high HC and CO concentrations.

5. The mobile high-power diesel-electric hybrid power system comprehensive performance test chamber as described in claim 1, characterized in that: The mobile cooling water system has a cooling water temperature of 32℃ and a water flow rate of 180t / h.

6. The mobile high-power diesel-electric hybrid power system comprehensive performance test chamber as described in claim 1, characterized in that: It also includes automated measurement and control systems, data acquisition systems, cooling systems, and infrastructure; Automated measurement and control systems include control instruments, cabinets, industrial computers and displays, software, uninterruptible power supplies, audible and visual indicator lights and displays, and emergency stop devices; The data acquisition system includes a data acquisition module, a hub box and bracket, thermocouples, sensors, a start / stop device, a throttle actuator and mounting bracket, an exhaust back pressure regulating device, and an intake pressure regulating device; the cooling system includes a water cooling system and a circulating air system. The infrastructure includes an electric dynamometer and its base, couplings, transition plates, fuel consumption measurement and control devices, engine intake and exhaust systems and outriggers, fuel supply systems, exhaust and smoke extraction systems, lighting systems, driving systems, water system modification components, sewage pipe modification components, high-pressure air pipe modification components, and electrical wiring modification components.

7. The mobile high-power diesel-electric hybrid power system comprehensive performance test chamber as described in claim 1, characterized in that: The working chamber of the test chamber measures 4000mm × 1400mm × 2000mm, with an internal volume of 11.2m³. 3 The external dimensions are designed based on the dimensions of the test bench.

8. The mobile high-power diesel-electric hybrid power system comprehensive performance test chamber as described in claim 1, characterized in that: The test chamber adopts an integrated design. Once the equipment is installed and the power is connected, it can be used. The test host is separated from and connected to the motor test bench through a track structure.

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