An aircraft simulator power control management system

Abstract

This utility model belongs to the field of aircraft simulator equipment, specifically an aircraft simulator power supply control and management system, including: a dual-channel mains power input unit, comprising: a first mains power module and a second mains power module; the first mains power module is connected to the input terminal of a UPS energy storage unit; the second mains power module is connected to the backup input port of an ATS automatic transfer switch; the main input port of the ATS automatic transfer switch is connected to the output terminal of the UPS energy storage unit through a voltage regulator module; the input terminal of the voltage regulator module is connected to the output terminal of the UPS energy storage unit, and the output terminal is connected to the input terminal of a redundant DC power supply unit, a cabinet cooling system, and load equipment respectively via a main control circuit; the redundant DC power supply unit is connected to the simulator terminal; the cabinet cooling system is thermally coupled to the redundant DC power supply system. This utility model solves the problem of traditional simulator power supply control systems having a single power supply circuit, which is prone to system downtime due to power fluctuations or faults.

Description

Technical Field

[0001] This utility model belongs to the field of aviation simulator equipment, specifically an aircraft simulator power supply control and management system. Background Technology

[0002] The aircraft simulator control and management unit is a dedicated power supply guarantee device for aviation system ground crew simulators. It provides comprehensive power guarantee for ground crew training, system integration testing, and fault simulation, becoming an indispensable infrastructure in the aviation simulation training system, and can significantly improve training efficiency and safety assurance level.

[0003] Traditional aircraft simulator power supply systems adopt the traditional mains direct power supply mode, and the specific problems are as follows: 1. Poor power supply reliability and weak anti-interference ability: (1) Single power input without redundancy backup: Relying on a single mains input, the system will directly lose power when there are grid fluctuations, lightning strikes or line faults, resulting in training interruption; There is no automatic switching mechanism, and power restoration depends on manual operation, which is slow (several minutes); (2) Lack of voltage stabilization and filtering measures: No professional voltage stabilization power supply is configured, and mains voltage fluctuations (such as ±10%) are directly transmitted to simulator equipment, affecting the stability of precision electronic components (such as simulation computers and avionics simulation modules); No EMI / EMC filtering design is adopted, and grid harmonics and surges can easily lead to data packet loss or equipment malfunction; 2. The protection mechanism is not perfect and the equipment is easily damaged: (1) Circuit breaker selection: It cannot identify instantaneous overload (such as motor starting current impact), and frequently trips the circuit breaker; (2) No buffer and soft start design: High-power equipment (such as foot pedal motor) starts directly, and the impact current can reach 5-7 times the rated value, which accelerates the aging of the circuit breaker or even damages it; and there is no UPS or supercapacitor backup, and the equipment will directly crash when the power is off, and the risk of data loss is high; 3. Poor system compatibility and scalability: Strong current and weak current are not isolated: Power lines and signal lines are arranged in parallel, and electromagnetic interference (EMI) causes communication errors. 4. Low operation and maintenance efficiency: Equipment start-up and shutdown need to be operated one by one, and it is easy to miss steps or make mistakes in the sequence; and there is no remote control function, and it is impossible to intervene quickly in an emergency; 5. Heat dissipation and energy efficiency problems: It only relies on natural convection heat dissipation, and the temperature inside the cabinet exceeds the limit (>60℃) when under high load, which leads to a shortened life of the power module.

[0004] To address the aforementioned shortcomings, technological innovation has been identified as a direction for the development of a new generation of power supply systems. The aim is to significantly improve the reliability, stability, and safety of the power supply system for aircraft simulators. Therefore, it is proposed to design an aircraft simulator power supply control and management system to solve the problems existing in the traditional aircraft simulator power supply system. Utility Model Content

[0005] The purpose of this invention is to provide a power supply control and management system for an aircraft simulator, in order to solve the problem that traditional simulator power supply control systems have a single power supply circuit and are prone to system downtime due to power fluctuations or faults.

[0006] The technical solution adopted by this utility model to achieve the above objectives is: a power supply control and management system for an aircraft simulator, comprising: a dual-channel mains power input module, a UPS energy storage unit, a voltage regulator module, a redundant DC power supply system, a main control circuit, an ATS automatic transfer switch, and a cabinet heat dissipation system;

[0007] The dual-channel AC power input unit includes: a first AC power module and a second AC power module;

[0008] The first AC power module is connected to the input terminal of the UPS energy storage unit via a leakage current protector QF1 to charge the UPS energy storage unit; the second AC power module is connected to the spare input port of the ATS automatic transfer switch via a leakage current protector QF2; and the main input port of the ATS automatic transfer switch is connected to the output terminal of the UPS energy storage unit via a voltage regulator module.

[0009] The input terminal of the UPS energy storage unit is connected to the first mains power supply, and the output terminal is connected to the main input port of the ATS automatic transfer switch.

[0010] The input terminal of the voltage regulator module is connected to the output terminal of the UPS energy storage unit, and the output terminal is connected to the input terminal of the redundant DC power supply unit, the cabinet heat dissipation system and the load equipment through the main control circuit, so as to achieve graded power-on and power-off sequence.

[0011] The redundant DC power supply unit is connected to the simulator terminal to supply power to the simulator terminal.

[0012] The cabinet cooling system is thermally coupled to the redundant DC power supply system to dynamically regulate the internal temperature of the cabinet.

[0013] The UPS energy storage unit includes: a UPS input module, a lithium battery module, a supercapacitor buffer module, and a UPS output module;

[0014] The input terminal of the lithium battery module is connected to the first AC power module through a leakage current protector QF1. After charging, it outputs stable AC power through an inverter.

[0015] The supercapacitor buffer module is connected in parallel with the UPS output module to buffer the instantaneous large current generated during motor startup; the UPS output module is connected to the input terminal of the voltage regulator module via circuit breaker QF3.

[0016] The voltage regulator module is a three-stage voltage regulator module, which includes: a high-frequency PWM voltage regulator unit, a DC-DC isolation unit, a dynamic PID adjustment unit, and a voltage regulator output terminal;

[0017] The high-frequency PWM voltage regulator unit serves as the first-stage voltage regulator module, and its output terminal is connected to the input terminal of the ATS automatic transfer switch.

[0018] The DC-DC isolation unit serves as the second-stage voltage regulator module. Its input is connected to the output of the high-frequency PWM voltage regulator unit, and its output is connected to the dynamic PID adjustment unit.

[0019] The dynamic PID adjustment unit, as the third-stage voltage regulation module, provides real-time feedback of the load voltage through a voltage sampling circuit and adjusts the PWM duty cycle to achieve output. Its output terminal is connected to the input terminal of the ATS automatic transfer switch via a regulated output terminal.

[0020] The output of the ATS automatic transfer switch is divided into two paths: one path supplies power to the redundant DC power supply module of 24V / 12V through circuit breakers QF7-QF14 via the main control circuit; the other path supplies power to the voltage regulator module, PDU power strip and cooling fan through circuit breakers QF3-QF6 via the main control circuit.

[0021] The main control circuit includes: a main contactor KM, a first time relay KT1, a second time relay KT2, a first grade contactor KM1, a second grade contactor KM2, a start button SB1, a first emergency stop button JT1, and a second emergency stop button JT2.

[0022] The main contactor KM is connected in series with the start button SB1 and the stop buttons JT1 / JT2 to form a control circuit; the normally open main contact KM-1 of the main contactor KM is connected to the input terminal of the voltage regulator module and the redundant DC power supply system; the auxiliary normally open contact KM-2 is self-locking to keep the main contactor KM in the energized state.

[0023] The power supply terminals of the first time relay KT1 and the second time relay KT2 are connected in parallel to the auxiliary normally open contact KM-2 of the main contactor KM, so that they are energized after the main contactor KM is energized; the normally open contact of the first time relay KT1 closes after a delay of ≥2 seconds to energize the coil of contactor KM1; the normally open contact of the second time relay KT2 closes after a delay of ≥3 seconds to energize the coil of contactor KM2.

[0024] The first hierarchical contactor KM1 is connected in series with the normally open contact of the first time relay KT1 to control the power supply of the fan and PDU1 power strip; the main contacts of the first hierarchical contactor KM1 are respectively connected to the circuit breakers QF3-QF6 and the cooling fan circuit breaker QF4 on the PDU1 power strip.

[0025] The second grade contactor KM2 is connected in series with the normally open contact of the second time relay KT2, and its main contacts are connected to QF6 of the PDU2 plug-in, the drive motor and the load device;

[0026] The first emergency stop button JT1 and the second emergency stop button JT2 are connected in series in the KM control circuit. After being triggered, the power supply to the KM coil is immediately cut off. At the same time, the load equipment connected to the second grade contactor KM2 is disconnected first through their respective auxiliary contacts, and the equipment connected to the first grade contactor KM1 is disconnected after a delay of ≥2 seconds.

[0027] The redundant DC power supply unit includes: a 24V power redundant module and a 12V power redundant module connected in parallel, as well as a PX1 terminal block and a PX2 terminal block.

[0028] The 24V power redundancy module is connected to the cabinet heat dissipation system, control board and drive motor respectively through PX2 terminal block;

[0029] The 12V power redundancy module is connected to the display device, the communication module and the data acquisition unit respectively through the PX1 terminal block;

[0030] Both the 24V power redundancy module and the 12V power redundancy module are equipped with leakage current protection devices at their output terminals.

[0031] Both the 24V and 12V power modules of the redundant DC power supply system are equipped with independent heat sinks and are connected to the PX1 / PX2 terminal blocks via hot-swappable interfaces.

[0032] The cabinet cooling system includes: multiple cooling fans, a temperature control sensor, and a control module;

[0033] The cooling fans are respectively installed on the top and rear wall of the cabinet to form a forced convection air duct; wherein, the air duct path of the cooling fans covers the voltage regulator module and redundant DC power supply module in the power supply control and management unit.

[0034] A temperature control sensor is installed inside the cabinet to monitor the cabinet temperature in real time. The temperature control sensor is an NTC thermistor, which is installed on the heat sink surface of the voltage regulator module and the redundant DC power supply module and is connected to the control module.

[0035] The control module is connected to the cooling fan and the temperature control sensor respectively, so as to dynamically adjust the speed of the cooling fan according to the feedback data of the temperature control sensor.

[0036] It also includes: an electromagnetic compatibility protection structure, which includes: independently set high-voltage cable trays, low-voltage cable trays, DC 12V cable trays and grounding cable trays;

[0037] The cable tray contains cables for a dual AC220V mains input unit, a UPS energy storage unit, and a voltage regulator module, and its exterior is coated with a red insulating layer for identification.

[0038] The low-voltage cable tray contains a DC24V temperature control sensor, a cooling fan, a control board, and a drive motor cable. The cable is coated with a blue insulating layer for identification, and the negative cable is coated with a white insulating layer.

[0039] The DC 12V cable tray is equipped with cables for DC 12V display devices, communication modules, and data acquisition units, and its exterior is coated with a green insulating layer for identification.

[0040] The grounding wire groove is equipped with a grounding wire, which is coated with a yellow-green bicolor insulation layer and is laid independently and connected to the cabinet grounding terminal.

[0041] Orthogonal routing is installed at cable intersections within each cable tray to minimize electromagnetic interference.

[0042] The high-voltage cable trays and low-voltage cable trays are laid in separate trays with a spacing of ≥10cm between the trays.

[0043] The high-voltage cables inside the high-voltage cable tray are wrapped with a metal braided shielding layer, and the two ends of the shielding layer are connected to the grounding terminal of the cabinet through conductive clips; the inner wall of the low-voltage cable tray is covered with a conductive coating to suppress electromagnetic coupling; at the same time, the low-voltage cables are connected to an EMI filter to filter out high-frequency noise.

[0044] This utility model has the following beneficial effects and advantages:

[0045] 1. This utility model has high power supply reliability: dual mains power input combined with ATS automatic transfer switch realizes seamless switching between main and backup power (response time ≤50ms), effectively avoiding system downtime caused by mains power fluctuations or faults; the supercapacitor buffer module works in conjunction with the UPS energy storage unit to provide instantaneous power support (≥5 seconds) when the mains power is interrupted, ensuring that critical equipment smoothly transitions to backup power and significantly reducing the risk of data loss.

[0046] 2. This utility model has enhanced stability and anti-interference capabilities: the three-stage voltage regulator module (high-frequency PWM + DC-DC isolation + dynamic PID regulation) can control the output voltage fluctuation within ±1%, while suppressing electromagnetic interference through EMI filtering and orthogonal wiring design, ensuring the stable operation of precision simulation equipment (such as avionics modules and data acquisition units).

[0047] 3. This utility model features graded protection and intelligent control: the main control circuit adopts a graded power-on sequence (first the heat dissipation system and low-power devices, then the high-power loads), combined with the emergency stop button to prioritize the disconnection of high-load devices and avoid current surges; the redundant DC power supply system (24V / 12V dual parallel) supports hot-swappable replacement, and a single module failure does not affect the overall power supply continuity.

[0048] 4. This utility model features dynamic heat dissipation optimization: the temperature control sensor is linked with the intelligent speed-regulating fan to monitor the temperature of key modules in real time (accuracy ±0.5℃), dynamically adjust the fan speed, stabilize the internal temperature of the cabinet within the range of 35-45℃, and extend the life of the power module (by ≥30%).

[0049] 5. This utility model features convenient operation and maintenance and scalability: the electromagnetic compatibility protection structure (slotted wiring + shielding layer design) simplifies cable management and reduces maintenance complexity; the modular design (such as redundant power supply and PDU power strip) supports rapid expansion and adapts to the needs of simulator equipment of different scales. Attached Figure Description

[0050] Figure 1 The schematic diagram of the main circuit of the control and management unit of this utility model;

[0051] Figure 2 The schematic diagram of the main control loop of the control management unit of this utility model. Detailed Implementation

[0052] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0053] like Figure 1 The diagram shown is the main circuit schematic of the control and management unit of this utility model. This utility model is a power supply control and management system for an aircraft simulator, including: a dual-channel mains power input module, a UPS energy storage unit, a voltage regulator module, a redundant DC power supply system, a main control circuit, an ATS automatic transfer switch, and a cabinet heat dissipation system.

[0054] The dual-channel AC power input unit includes: a first AC power module and a second AC power module;

[0055] The first AC power module is connected to the input terminal of the UPS energy storage unit via a leakage current protector QF1 to charge the UPS energy storage unit; the second AC power module is connected to the spare input port of the ATS automatic transfer switch via a leakage current protector QF2; and the main input port of the ATS automatic transfer switch is connected to the output terminal of the UPS energy storage unit via a voltage regulator module.

[0056] The input terminal of the UPS energy storage unit is connected to the first mains power supply, and the output terminal is connected to the main input port of the ATS automatic transfer switch;

[0057] The input terminal of the voltage regulator module is connected to the output terminal of the UPS energy storage unit, and the output terminal is connected to the input terminal of the redundant DC power supply unit, the cabinet heat dissipation system and the load equipment through the main control circuit, so as to achieve graded power-on and power-off sequence.

[0058] The redundant DC power supply unit is connected to the simulator terminal to supply power to the simulator terminal;

[0059] The cabinet cooling system is thermally coupled to the redundant DC power supply system to dynamically regulate the internal temperature of the cabinet.

[0060] (a) UPS energy storage unit

[0061] The UPS energy storage unit includes: UPS input module, lithium battery module, supercapacitor buffer module, and UPS output module;

[0062] The input terminal of the lithium battery module is connected to the first AC power module through the leakage current protector QF1. After charging, it outputs stable AC power through the inverter.

[0063] The supercapacitor buffer module is connected in parallel with the UPS output module to buffer the instantaneous large current generated during motor startup; the UPS output module is connected to the input terminal of the voltage regulator module via circuit breaker QF3.

[0064] (ii) Voltage Regulator Module

[0065] The voltage regulator module is a three-stage voltage regulator module, which includes: a high-frequency PWM voltage regulator unit, a DC-DC isolation unit, a dynamic PID adjustment unit, and a regulated output terminal;

[0066] The high-frequency PWM voltage regulator unit serves as the first-stage voltage regulator module, and its output is connected to the input of the ATS automatic transfer switch.

[0067] The DC-DC isolation unit serves as the second-stage voltage regulator module. Its input is connected to the output of the high-frequency PWM voltage regulator unit, and its output is connected to the dynamic PID adjustment unit.

[0068] The dynamic PID control unit, as the third-stage voltage regulation module, provides real-time feedback of the load voltage through a voltage sampling circuit and adjusts the PWM duty cycle to achieve output. Its output is connected to the input of the ATS automatic transfer switch via a regulated output terminal.

[0069] (iii) ATS Automatic Transfer Switch

[0070] The output of the ATS automatic transfer switch is divided into two paths: one path supplies power to the redundant DC power supply module of 24V / 12V through circuit breakers QF7-QF14 via the main control circuit; the other path supplies power to the voltage regulator module, PDU power strip and cooling fan through circuit breakers QF3-QF6 via the main control circuit.

[0071] (iv) Main control circuit

[0072] like Figure 2The diagram shown is a schematic of the main control circuit of the control management unit of this utility model. The main control circuit includes: a main contactor KM, a first time relay KT1, a second time relay KT2, a first grade contactor KM1, a second grade contactor KM2, a start button SB1, a first emergency stop button JT1, and a second emergency stop button JT2.

[0073] The main contactor KM is connected in series with the start button SB1 and the stop buttons JT1 / JT2 to form a control circuit; the normally open main contact KM-1 of the main contactor KM is connected to the input terminal of the voltage regulator module and the redundant DC power supply system; the auxiliary normally open contact KM-2 is self-locking to keep the main contactor KM in the energized state.

[0074] The power supply terminals of the first time relay KT1 and the second time relay KT2 are connected in parallel to the auxiliary normally open contact KM-2 of the main contactor KM, so that they are energized after the main contactor KM is energized; the normally open contact of the first time relay KT1 closes after a delay of ≥2 seconds, controlling the coil of contactor KM1 to be energized; the normally open contact of the second time relay KT2 closes after a delay of ≥3 seconds, controlling the coil of contactor KM2 to be energized.

[0075] The first-level contactor KM1 is connected in series with the normally open contact of the first time relay KT1 to control the power supply of the fan and PDU1 power strip; the main contacts of the first-level contactor KM1 are respectively connected to the circuit breakers QF3-QF6 and the cooling fan circuit breaker QF4 on the PDU1 power strip.

[0076] The second-stage contactor KM2 is connected in series with the normally open contact of the second time relay KT2, and its main contacts are connected to QF6 of the PDU2 plug-in, the drive motor and the load device;

[0077] The first emergency stop button JT1 and the second emergency stop button JT2 are connected in series in the KM control circuit. Upon triggering, the power supply to the KM coil is immediately cut off. At the same time, the load equipment connected to the second grade contactor KM2 is disconnected first through their respective auxiliary contacts, and the equipment connected to the first grade contactor KM1 is disconnected after a delay of ≥2 seconds.

[0078] (v) Redundant DC power supply unit

[0079] The redundant DC power supply unit includes: a 24V power redundant module and a 12V power redundant module connected in parallel, as well as PX1 terminal block and PX2 terminal block.

[0080] The 24V power redundancy module is connected to the cabinet cooling system, control board and drive motor respectively through PX2 terminal block;

[0081] The 12V power redundancy module is connected to the display device, communication module and data acquisition unit respectively through the PX1 terminal block;

[0082] Both the 24V power supply redundancy module and the 12V power supply redundancy module are equipped with leakage current protection devices at their output terminals.

[0083] Both the 24V and 12V power modules of the redundant DC power supply system are equipped with independent heat sinks and are connected to the PX1 / PX2 terminal blocks via hot-swappable interfaces.

[0084] (vi) Cabinet cooling system

[0085] The rack cooling system includes: multiple cooling fans, temperature control sensors, and a control module;

[0086] Cooling fans are installed on the top and rear wall of the cabinet to form a forced convection airflow duct; wherein the airflow path of the cooling fans covers the voltage regulator module and redundant DC power supply module in the power supply control and management unit.

[0087] A temperature control sensor is installed inside the cabinet to monitor the cabinet temperature in real time. The temperature control sensor is an NTC thermistor, which is installed on the heat sink surface of the voltage regulator module and the redundant DC power supply module and is connected to the control module.

[0088] The control module is connected to both the cooling fan and the temperature sensor to dynamically adjust the speed of the cooling fan based on feedback data from the temperature sensor.

[0089] (vii) Other structures

[0090] The electromagnetic compatibility protection structure includes: independently set high-voltage cable trays, low-voltage cable trays, DC 12V cable trays, and grounding cable trays;

[0091] The power cable tray contains cables for a dual AC220V mains input unit, a UPS energy storage unit, and a voltage regulator module, and its exterior is coated with a red insulating layer for identification.

[0092] The low-voltage cable tray contains a DC24V temperature control sensor, a cooling fan, a control board, and a drive motor cable. The cable is coated with a blue insulating layer for identification, and the negative cable is coated with a white insulating layer.

[0093] The DC 12V cable tray contains cables for DC 12V display devices, communication modules, and data acquisition units, and its exterior is coated with a green insulating layer for identification.

[0094] The grounding wire is installed in the grounding wire trough. The outside of the grounding wire is coated with a yellow-green double-color insulation layer and is laid independently and connected to the grounding terminal of the cabinet.

[0095] Orthogonal routing is installed at cable intersections within each cable tray to minimize electromagnetic interference.

[0096] High-voltage cables and low-voltage cables should be laid in separate troughs, with a spacing of ≥10cm between the troughs.

[0097] The high-voltage cables inside the power cable tray are wrapped with a metal braided shielding layer, and the two ends of the shielding layer are connected to the grounding terminal of the cabinet through conductive clips; the inner wall of the low-voltage cable tray is covered with a conductive coating to suppress electromagnetic coupling; at the same time, the low-voltage cables are connected to an EMI filter to filter out high-frequency noise.

[0098] The working principle of this utility model is as follows:

[0099] like Figures 1-2 As shown, the working principle of this utility model is specifically as follows:

[0100] (1) Dual-path mains power access and switching:

[0101] In this embodiment, both the first and second AC power modules use an input power supply of AC 220V / 50Hz, with an allowable voltage fluctuation of ±10% (i.e., 198V~242V); output stability: after voltage regulation, the output voltage fluctuation is ≤±3%; protection functions: it has leakage current, overcurrent, overload, and overvoltage protection, with a response time ≤20ms.

[0102] The first AC power module (main power) is connected to the UPS energy storage unit through the leakage current protector QF1 to charge its lithium battery module; the second AC power module (backup power) is connected to the backup port of the ATS automatic transfer switch via QF2.

[0103] When the main power supply fails, the ATS automatic transfer switch (response time ≤20ms) switches to the backup power supply, and at the same time the UPS energy storage unit outputs stable AC power through the inverter to ensure uninterrupted system operation.

[0104] (2) Voltage stabilization and power distribution:

[0105] The AC power output from the UPS is processed by a three-stage voltage regulation module: a high-frequency PWM voltage regulation unit eliminates high-frequency noise, a DC-DC isolation unit achieves strong and weak current isolation, and a dynamic PID adjustment unit adjusts the duty cycle through real-time voltage sampling, ultimately outputting a stable voltage with ±1% accuracy.

[0106] After voltage regulation, the power supply is divided into two paths through the main control circuit: one path supplies power to the 24V / 12V redundant DC power supply module through QF7-QF14; the other path supplies power to the PDU power strip, cooling fan and drive motor through QF3-QF6.

[0107] (3) Hierarchical power-on control:

[0108] Press the start button SB1, the main contactor KM is energized and self-locked, the first time relay KT1 (delayed for 2 seconds) controls KM1 to close, starting the cooling fan and PDU1 power strip; the second time relay KT2 (delayed for 3 seconds) controls KM2 to close, starting the drive motor and high power load, avoiding instantaneous current surges.

[0109] When the emergency stop button JT1 / JT2 is triggered, the power supply to the KM coil is immediately cut off, the load device of KM2 (such as the motor) is disconnected first, and the device of KM1 (such as the PDU power strip) is disconnected 2 seconds later to ensure the safe shutdown of the system.

[0110] (4) Heat dissipation and temperature management:

[0111] The temperature sensor (NTC thermistor) monitors the temperature of the voltage regulator module and the redundant power supply heat sink in real time and feeds it back to the control module;

[0112] When the temperature is >40℃, the control module increases the speed of the top and rear wall cooling fans to 80% to force the convection air duct to cool down quickly; when the temperature is <35℃, the fans switch to low speed mode (30%) to reduce energy consumption and noise.

[0113] (5) Implementation of electromagnetic compatibility protection:

[0114] High-voltage cables (marked in red) and low-voltage cables (marked in blue / green) should be laid in separate trenches (with a spacing of ≥10cm), and orthogonal routing should be used at intersections;

[0115] The high-voltage cables are wrapped with a metal braided shield and grounded at both ends; the inner wall of the low-voltage cable tray is coated with a conductive coating and connected to an EMI filter to effectively suppress common-mode interference and high-frequency noise.

[0116] Example 1:

[0117] 1. Dual-channel AC power input unit

[0118] The dual-channel AC power input unit in this embodiment adopts an AC power supply system, and its technical specifications are as follows:

[0119] Input power: AC 220V / 50Hz, allowable voltage fluctuation ±10% (i.e., 198V~242V); Output stability: after regulation, output voltage fluctuation ≤±3%; Protection functions: equipped with leakage current, overcurrent, overload and overvoltage protection, response time ≤20ms;

[0120] Implementation plan:

[0121] The regulated power supply uses a contactor-type AC voltage regulator, model SVC(TND / TNS), manufactured by People's Electric Appliance Group Co., Ltd. It is a three-stage regulated power supply, consisting of a contact-type autotransformer, a servo motor, and an automatic control circuit. When the mains voltage is unstable or the load changes, the automatic control circuit drives the servo motor to adjust the position of the carbon brushes on the contact-type autotransformer according to the output voltage change, adjusting the voltage to the rated value before outputting. The voltage regulator provides a stable, reliable, and efficient output voltage, and can operate continuously for extended periods.

[0122] 2. Redundant DC power supply unit

[0123] The 24V power supply redundancy module uses a 24V industrial-grade power supply with a ripple factor ≤0.1% and is a redundancy module (2+1 backup); the 12V power supply redundancy module uses a 12V industrial-grade power supply with a ripple factor ≤0.1% and is a redundancy module (2+1 backup).

[0124] Implementation plan:

[0125] Power module: Uses Mean Well SDR and NDR series high-precision switching power supplies with ripple <150mVp-p;

[0126] Redundant design: Parallel redundant modules support hot-swappable replacement and seamless switching in case of single module failure;

[0127] Power capacity: Meets the peak load requirements of all DC devices (such as sensors and control boards);

[0128] The redundant DC power supply unit in this embodiment can use a 20A redundant module from the DRDN20 series, which can be paired with the power supply to improve the reliability of system operation. Key features of the product include: selectable 12V / 24V / 48V input voltages; support for N+1 and 1+1 redundant systems; built-in two DC input terminals and a single output terminal; use of MOSFET technology to reduce heat loss and minimize the voltage difference between input and output; built-in two DCOK relay contacts for monitoring output status; and an ultra-wide operating temperature range of -40℃ to +80℃.

[0129] 3. UPS energy storage unit (emergency power supply)

[0130] Battery life: After a dual-circuit mains power failure, the UPS can independently supply power for ≥15 minutes;

[0131] Switching time: Mains power to UPS switching ≤10ms, without interruption;

[0132] Implementation plan:

[0133] This embodiment uses a dual-purpose (vertical and horizontal) uninterruptible power supply, which is equipped with UPS lithium battery energy storage (RCKS series), supports fast charging and discharging with a time interval of 4ms; and supercapacitor buffer to cope with instantaneous high current demand (such as motor starting).

[0134] 4. Main control circuit

[0135] (1) Remote start / stop and delay control

[0136] a. Supports one-click start / stop for both the console and remote terminals;

[0137] b. PDU2 (devices belonging to the power strip), drive motor delayed start (e.g., staged power-on, with an interval of more than 2 seconds).

[0138] c. When power is lost, PDU2 (the device to which the power strip belongs) and drive motor are delayed in cutting off power (to prevent data loss).

[0139] Implementation plan:

[0140] a. Design the control circuit using a contactor (in this embodiment, the Chint CJX series is selected);

[0141] b. Time relay (Chint JSZ3 series is selected in this embodiment) for precise control of delay;

[0142] 5. Automatic Dual Power Supply Switch (ATS)

[0143] The switching time between main and backup power supplies is ≤0.5 seconds, with mechanical / electrical interlocks to prevent parallel connection of dual power supplies.

[0144] Implementation plan:

[0145] The ATS module (in this embodiment, the switching switch model RDQ5-125 / 2P 32A is selected) supports automatic switching based on voltage detection;

[0146] 6. Rack design and heat dissipation

[0147] This embodiment uses a multi-directional cooling fan (top + rear wall); the airflow is optimized to ensure that the hot spot temperature is ≤60℃.

[0148] Rack selection: Rittal series racks, modular design, with 20% space reserved for expansion;

[0149] An axial fan is selected, with a noise level of <50dB;

[0150] 7. Other structures

[0151] Emergency stop function:

[0152] Equipped with an emergency stop button (compliant with IEC 60947-5 standard) to cut off all power output;

[0153] EMC electromagnetic protection:

[0154] High-voltage and low-voltage cables are color-coded for isolation (AC 220V red, DC 24V blue);

[0155] 8. Assemble and run

[0156] like Figure 1 As shown, this embodiment of the system is configured with dual power supplies (a first mains power module and a second mains power module) to prevent the normal operation of the equipment from being affected when one of the mains power supplies is unexpectedly interrupted.

[0157] An uninterruptible power supply (UPS) energy storage unit is installed on the main circuit of the first mains module. During normal power-on operation, the UPS energy storage unit is continuously charged to ensure that it can continuously provide uninterrupted power to the entire system in the event of a power failure of the first mains module. A voltage regulator is installed below the UPS energy storage unit to ensure that the output voltage of the power from the mains to the UPS energy storage unit is stable within ±3% after passing through the voltage regulator, thus ensuring the quality of the power supply voltage.

[0158] A dual power supply switch is connected after the regulated power supply. The other input terminal of the switch is connected to the main power supply of the second mains module. This ensures that when the first mains module is powered off during the operation of both power supplies, the second mains module continues to supply power through the dual power supply switch.

[0159] like Figure 2 As shown, the system startup process is as follows:

[0160] All circuit breakers are in the closed state. When the system starts, press the start button SB1. After the main contactor KM is energized, the coils of time relays KT1 and KT2 are energized and start timing respectively. The normally open contact of KM is energized, and the PDU1 power strip / 1#, 2#, 3#, and 4# 24V and 12V power supplies are powered on. After power-on, the 1# 24V redundant power supply, 2# 24V redundant power supply, 1# 12V redundant power supply, and 2# 12V redundant power supply are energized to supply power to the subsequent subsystems (acquisition system, motor drive, visual system, etc.).

[0161] To avoid all devices starting up at the same time and reduce inrush current, firstly, the normally open contact of KT1 closes, energizing the coil of contactor KM1. Then, the normally open contact of KM1 closes, and the fan in the power supply system starts running to cool the control unit. Then, the normally open contact of KT2 closes, powering on all devices connected to the PDU2 connector.

[0162] System shutdown process:

[0163] The JT1 and JT2 stop buttons allow for local or remote shutdown control. Pressing either button will cause the equipment to enter a shutdown state.

[0164] Verification of the effect of this embodiment:

[0165] In a field test at an aviation training center, the system of this embodiment maintained a stable output voltage of 220V±2V under fluctuating mains voltage (180V-250V); the internal temperature of the cabinet remained ≤45℃ during 8 hours of continuous simulator operation; and the equipment operated without interruption during dual-power switching tests, with the data packet loss rate reduced to 0.01%. This verifies its significant improvement in reliability, stability, and security.

[0166] Furthermore, the performance of this embodiment, compared with that of a traditional aircraft simulator power supply system, demonstrates a comprehensive optimization and upgrade, as detailed below:

[0167] 1. Power supply reliability has been greatly improved, as shown in Table 1.

[0168] Table 1

[0169] Comparison items Original plan This utility model Advantages and effects Power redundancy Single-circuit AC power supply, no backup Dual AC power supply + ATS automatic switching + UPS To avoid single points of failure, the switching time is ≤0.5 seconds, and the battery life after a power outage is ≥15 minutes. Protection mechanism Overcurrent protection only Full protection against overvoltage, undervoltage, leakage, and overload. Response time ≤20ms

[0170] Actual benefits:

[0171] The risk of system downtime is reduced by 90%, meeting the continuous training requirements of aircraft simulators.

[0172] 2. Power quality and stability have been significantly improved, as shown in Table 2.

[0173] Table 2

[0174] Comparison items Original plan This utility model Advantages and effects voltage fluctuation Directly transmits grid fluctuations (±10%) Three-stage voltage regulation, output ±2%. Protecting sophisticated avionics equipment (such as flight control computers) Ripple coefficient Uncontrolled (typically >1%) DC power supply ripple ≤0.1% Ensure that sensors and communication signals are distortion-free.

[0175] Actual benefits:

[0176] The accuracy of the simulated training data has improved, and the false alarm rate has decreased by 80%.

[0177] 3. The level of intelligence and automation has improved, as shown in Table 3.

[0178] Table 3

[0179] Comparison items Original plan This utility model Advantages and effects Equipment start-up and shutdown Manual operation of each machine Relay-controlled one-button start / stop The starting inrush current has been reduced to 1.5 times. Remote Management none Supports remote start / stop and status monitoring Operation and maintenance efficiency improved by 50%

[0180] Actual benefits:

[0181] Training preparation time has been reduced from 10 minutes to within 30 seconds.

[0182] In conjunction with Embodiment 1 of this utility model, the key innovation of this utility model lies in:

[0183] ① Dual power redundancy + intelligent switching system

[0184] a. It adopts dual-channel AC power input + ATS automatic switching, with independent isolation between main and backup power supplies, and a switching time of ≤0.5 seconds, which is better than traditional manual switching (more than 2 seconds).

[0185] b. UPS + supercapacitor hybrid energy storage ensures that the system can continue to operate for ≥15 minutes when both power sources fail, and supports fast charging;

[0186] ② High-precision voltage regulation and dynamic adjustment

[0187] a. Three-stage voltage regulation design (input voltage regulation + DC-DC isolation + dynamic PID adjustment), output voltage fluctuation ≤ ±3%;

[0188] b. Adaptable to a wide input voltage range (160V~250V) to meet the ±10% fluctuation requirements of the power grid;

[0189] ③ Intelligent timing control and protection

[0190] a. After one-key triggering, devices such as PDU2 and drive motor are powered on in stages according to preset delays (such as 3-second intervals), reducing the inrush current to within 1.5 times the rated value (5-7 times in traditional solutions).

[0191] b. Emergency stop and delayed power outage: In case of emergency stop, prioritize data preservation of critical equipment (such as computers) before disconnecting high-power loads such as drive motors;

[0192] ④ Modular DC power supply system

[0193] a. 24V / 12V industrial-grade redundant power supply module (2+1 backup), ripple coefficient ≤0.1%, supports hot-swappable replacement, avoiding single point of failure;

[0194] ⑤ EMC optimization and heat dissipation design

[0195] a. High-voltage / low-voltage isolation wiring: Red wire (AC 220V) and blue wire (DC 24V) are laid in separate channels to reduce electromagnetic interference (compliant with DO-160G standard).

[0196] b. Intelligent temperature-controlled air-cooling system: multi-directional fans (top + rear wall) to ensure cabinet temperature ≤60℃.

[0197] In summary, this invention successfully constructs a highly reliable and stable power supply control and management system for aircraft simulators through an innovative dual-power redundant architecture, three-level dynamic voltage regulation technology, and intelligent timing control mechanism. Actual testing has verified that the system can still stably output 220V±2V even under severe mains power fluctuations (180V-250V), with cabinet temperature rise controlled below 45℃, and data packet loss rate reduced to 0.01%. Compared to traditional solutions, this represents a 90% improvement in power supply reliability and an 80% reduction in malfunction rate, fully meeting the stringent requirements of continuity, accuracy, and safety in aviation simulation training.

[0198] In the future, this system can be further integrated with IoT remote monitoring functions to achieve real-time diagnosis and predictive maintenance of power supply status. This invention is not only applicable to the field of aviation simulators, but can also be extended to high-precision power supply scenarios such as rail transit simulation and ship driving simulation, providing a benchmark-level power supply solution for critical training facilities.

[0199] Those skilled in the art will understand that the above description is merely a preferred embodiment of the present invention, and the various embodiments and / or features described in the claims can be combined or combined in various ways, even if such combinations or combinations are not explicitly described in this disclosure. This is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

[0200] Although preferred embodiments of the present invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the present invention. Clearly, those skilled in the art can make various alterations and modifications to the present invention without departing from its spirit and scope. Thus, if these modifications and modifications of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention also intends to include these modifications and modifications.

Claims

1. An aircraft simulator power supply control management system, characterized by, include: Dual-channel AC power input module, UPS energy storage unit, voltage regulator module, redundant DC power supply system, main control circuit, ATS automatic transfer switch, and cabinet heat dissipation system; The dual-channel AC power input unit includes: a first AC power module and a second AC power module; The first AC power module is connected to the input terminal of the UPS energy storage unit via a leakage current protector QF1 to charge the UPS energy storage unit; the second AC power module is connected to the spare input port of the ATS automatic transfer switch via a leakage current protector QF2; and the main input port of the ATS automatic transfer switch is connected to the output terminal of the UPS energy storage unit via a voltage regulator module. The input terminal of the UPS energy storage unit is connected to the first mains power supply, and the output terminal is connected to the main input port of the ATS automatic transfer switch. The input terminal of the voltage regulator module is connected to the output terminal of the UPS energy storage unit, and the output terminal is connected to the input terminal of the redundant DC power supply unit, the cabinet heat dissipation system and the load equipment through the main control circuit, so as to achieve graded power-on and power-off sequence. The redundant DC power supply unit is connected to the simulator terminal to supply power to the simulator terminal. The cabinet cooling system is thermally coupled to the redundant DC power supply system to dynamically regulate the internal temperature of the cabinet.

2. An aircraft simulator power supply control management system according to claim 1, wherein, The UPS energy storage unit includes: a UPS input module, a lithium battery module, a supercapacitor buffer module, and a UPS output module; The input terminal of the lithium battery module is connected to the first AC power module through a leakage current protector QF1. After charging, it outputs stable AC power through an inverter. The supercapacitor buffer module is connected in parallel with the UPS output module to buffer the instantaneous large current generated during motor startup; the UPS output module is connected to the input terminal of the voltage regulator module via circuit breaker QF3.

3. The power supply control management system for an aircraft simulator of claim 1, wherein, The voltage regulator module is a three-stage voltage regulator module, which includes: a high-frequency PWM voltage regulator unit, a DC-DC isolation unit, a dynamic PID adjustment unit, and a voltage regulator output terminal; The high-frequency PWM voltage regulator unit serves as the first-stage voltage regulator module, and its output terminal is connected to the input terminal of the ATS automatic transfer switch. The DC-DC isolation unit serves as the second-stage voltage regulator module. Its input is connected to the output of the high-frequency PWM voltage regulator unit, and its output is connected to the dynamic PID adjustment unit. The dynamic PID adjustment unit, as the third-stage voltage regulation module, provides real-time feedback of the load voltage through a voltage sampling circuit and adjusts the PWM duty cycle to achieve output. Its output terminal is connected to the input terminal of the ATS automatic transfer switch via a regulated output terminal.

4. The power supply control management system for an aircraft simulator of claim 1, wherein, The output of the ATS automatic transfer switch is divided into two paths: one path supplies power to the redundant DC power supply module of 24V / 12V through circuit breakers QF7-QF14 via the main control circuit; the other path supplies power to the voltage regulator module, PDU power strip and cooling fan through circuit breakers QF3-QF6 via the main control circuit.

5. An aircraft simulator power supply control management system according to claim 1 or 4, wherein, The main control circuit includes: a main contactor KM, a first time relay KT1, a second time relay KT2, a first grade contactor KM1, a second grade contactor KM2, a start button SB1, a first emergency stop button JT1, and a second emergency stop button JT2. The main contactor KM is connected in series with the start button SB1 and the stop buttons JT1 / JT2 to form a control circuit; the normally open main contact KM-1 of the main contactor KM is connected to the input terminal of the voltage regulator module and the redundant DC power supply system; the auxiliary normally open contact KM-2 is self-locking to keep the main contactor KM in the energized state. The power supply terminals of the first time relay KT1 and the second time relay KT2 are connected in parallel to the auxiliary normally open contact KM-2 of the main contactor KM, so that they are energized after the main contactor KM is energized; the normally open contact of the first time relay KT1 closes after a delay of ≥2 seconds to energize the coil of contactor KM1; the normally open contact of the second time relay KT2 closes after a delay of ≥3 seconds to energize the coil of contactor KM2. The first hierarchical contactor KM1 is connected in series with the normally open contact of the first time relay KT1 to control the power supply of the fan and PDU1 power strip; the main contacts of the first hierarchical contactor KM1 are respectively connected to the circuit breakers QF3-QF6 and the cooling fan circuit breaker QF4 on the PDU1 power strip. The second grade contactor KM2 is connected in series with the normally open contact of the second time relay KT2, and its main contacts are connected to QF6 of the PDU2 plug-in, the drive motor and the load device; The first emergency stop button JT1 and the second emergency stop button JT2 are connected in series in the KM control circuit. After being triggered, the power supply to the KM coil is immediately cut off. At the same time, the load equipment connected to the second grade contactor KM2 is disconnected first through their respective auxiliary contacts, and the equipment connected to the first grade contactor KM1 is disconnected after a delay of ≥2 seconds.

6. The power supply control management system for an aircraft simulator of claim 1, wherein, The redundant DC power supply unit includes: a 24V power redundant module and a 12V power redundant module connected in parallel, as well as a PX1 terminal block and a PX2 terminal block. The 24V power redundancy module is connected to the cabinet heat dissipation system, control board and drive motor respectively through PX2 terminal block; The 12V power redundancy module is connected to the display device, the communication module and the data acquisition unit respectively through the PX1 terminal block; Both the 24V power redundancy module and the 12V power redundancy module are equipped with leakage current protection devices at their output terminals.

7. An aircraft simulator power supply control management system according to claim 6, wherein, Both the 24V and 12V power modules of the redundant DC power supply system are equipped with independent heat sinks and are connected to the PX1 / PX2 terminal blocks via hot-swappable interfaces.

8. The power supply control management system for an aircraft simulator of claim 1, wherein, The cabinet cooling system includes: multiple cooling fans, a temperature control sensor, and a control module; The cooling fans are respectively installed on the top and rear wall of the cabinet to form a forced convection air duct; wherein, the air duct path of the cooling fans covers the voltage regulator module and redundant DC power supply module in the power supply control and management unit. A temperature control sensor is installed inside the cabinet to monitor the cabinet temperature in real time. The temperature control sensor is an NTC thermistor, which is installed on the heat sink surface of the voltage regulator module and the redundant DC power supply module and is connected to the control module. The control module is connected to the cooling fan and the temperature control sensor respectively, so as to dynamically adjust the speed of the cooling fan according to the feedback data of the temperature control sensor.

9. The power supply control management system for an aircraft simulator of claim 1, wherein, Also includes: The electromagnetic compatibility protection structure includes: independently set high-voltage cable trays, low-voltage cable trays, DC 12V cable trays, and grounding cable trays; The cable tray contains cables for a dual AC220V mains input unit, a UPS energy storage unit, and a voltage regulator module, and its exterior is coated with a red insulating layer for identification. The low-voltage cable tray contains a DC24V temperature control sensor, a cooling fan, a control board, and a drive motor cable. The cable is coated with a blue insulating layer for identification, and the negative cable is coated with a white insulating layer. The DC 12V cable tray is equipped with cables for DC 12V display devices, communication modules, and data acquisition units, and its exterior is coated with a green insulating layer for identification. The grounding wire groove is equipped with a grounding wire, which is coated with a yellow-green bicolor insulation layer and is laid independently and connected to the cabinet grounding terminal. Orthogonal routing is installed at cable intersections within each cable tray to minimize electromagnetic interference.

10. An aircraft simulator power supply control management system according to claim 9, wherein, The high-voltage cable trays and low-voltage cable trays are laid in separate trays with a spacing of ≥10cm between the trays. The high-voltage cables inside the high-voltage cable tray are wrapped with a metal braided shielding layer, and the two ends of the shielding layer are connected to the grounding terminal of the cabinet through conductive clips; the inner wall of the low-voltage cable tray is covered with a conductive coating to suppress electromagnetic coupling; at the same time, the low-voltage cables are connected to an EMI filter to filter out high-frequency noise.

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