Test Bench Control Using Virtual Torque and Speed Estimation
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Solution Overview
Problem
Existing test bench technologies face challenges in accurately estimating specimen rotational speed and torque, particularly in electric motor test benches, due to the lack of direct measurement capabilities and high complexity of existing models, which can lead to operational inefficiencies and potential damage.
Innovation Solution
A method using a first system of differential equations to model the rotational behavior of a test bench arrangement, combined with an autonomous system of differential equations to estimate specimen rotational speed and torque, employing exosystems to decouple and enhance model accuracy without increasing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are installed to measure all test bench variables directly, then measurement precision and control accuracy are improved, but device complexity and costs increase significantly
Solution Approach 1:
The patent creates virtual copies of physical sensors through mathematical models. Instead of installing physical sensors to measure specimen rotational speed and torque, the system uses a virtual sensor model that calculates these values from measurements of other variables (loading machine rotational speed, torques, and mechanical connection parameters). This virtual copying approach achieves the same measurement precision as physical sensors would provide, while avoiding the complexity and cost of installing additional hardware sensors throughout the test bench.
Solution Approach 2:
The patent introduces mathematical models and calculation algorithms as intermediaries between the physical measurement system and the control system. Rather than directly measuring all required variables with physical sensors, the system uses measured variables as inputs to mathematical models that compute the desired specimen parameters. This intermediary computational layer transforms available measurements into the needed measurement information without requiring direct physical sensing of all variables.
2Device complexity
If fewer sensors are used to reduce complexity and cost, then device complexity is reduced, but measurement precision and control accuracy deteriorate
Solution Approach 1:
The patent creates virtual copies of physical sensors through mathematical models. Instead of installing physical sensors to measure specimen rotational speed and torque, the system uses a virtual sensor model that calculates these values from measurements of other variables (loading machine rotational speed, torques, and mechanical connection parameters). This virtual copying approach achieves the same measurement precision as physical sensors would provide, while avoiding the complexity and cost of installing additional hardware sensors throughout the test bench.
Solution Approach 2:
The system implements a feedback mechanism where the mathematical models continuously compute specimen parameters based on current measurements, and these computed values are fed back to the control system for real-time control decisions. The feedback loop ensures that even though fewer physical sensors are used, the control system receives accurate, up-to-date information about specimen state, maintaining measurement precision equivalent to having direct sensors on all components.
3Measurement precision
If complex mathematical models are used to estimate specimen parameters, then measurement precision is improved, but device complexity and computational requirements increase
Solution Approach 1:
The patent segments the complex estimation problem into distinct computational modules: a mechanical connection model that handles torque transmission calculations, a specimen model that processes rotational dynamics, and a control module that implements damping control. Each segment processes specific aspects of the parameter estimation independently, which reduces the complexity of individual computational blocks while maintaining the overall precision of the integrated system.
Solution Approach 2:
The patent introduces mathematical models and calculation algorithms as intermediaries between the physical measurement system and the control system. Rather than directly measuring all required variables with physical sensors, the system uses measured variables as inputs to mathematical models that compute the desired specimen parameters. This intermediary computational layer transforms available measurements into the needed measurement information without requiring direct physical sensing of all variables.
4Measurement precision
If direct measurement of specimen rotational speed and torque is implemented, then measurement precision is improved, but the number of sensors and wiring complexity increase
Solution Approach 1:
The patent creates virtual copies of physical sensors through mathematical models. Instead of installing physical sensors to measure specimen rotational speed and torque, the system uses a virtual sensor model that calculates these values from measurements of other variables (loading machine rotational speed, torques, and mechanical connection parameters). This virtual copying approach achieves the same measurement precision as physical sensors would provide, while avoiding the complexity and cost of installing additional hardware sensors throughout the test bench.
Solution Approach 2:
The patent makes the loading machine's measurement system serve multiple functions. The same sensors and measurement infrastructure used to monitor loading machine operation are also utilized as inputs for computing specimen parameters. This multi-functionality allows the system to obtain specimen rotational speed and torque information without requiring dedicated sensors on the specimen, thereby reducing the total number of sensors needed while maintaining measurement precision.
Data Source
AI summary
In order to provide a method that improves on the prior art for controlling a test bench arrangement in which a rotating specimen is connected to a rotating loading machine via a mechanical shaft connection and in which at least one angular velocity prevailing in the test bench arrangement is measured, the rotational behavior of the test bench arrangement and thus the dynamic behavior at least of the measured angular velocity and of a specimen angular velocity (ωP) prevailing in the specimen is first of all modeled using a first system of differential equations. Building on this, the specimen torque (TP) generated by the specimen is modeled using a second system of differential equations, a state observer for estimating the specimen angular velocity (ωP) and the specimen torque (TP) is designed on the basis of the first and second system of differential equations, estimates of the specimen angular velocity (ω{circumflex over ( )}_P) and of the specimen torque ({circumflex over (T)}ρ) are determined by means of the state observer, and the determined estimates are used to control at least one control angular velocity prevailing in the test bench arrangement (4) and/or at least one control torque prevailing in the test bench arrangement.