应急柴油发电机组调速系统测试平台设计

    Design of the Test Platform for Speed Control Systems of Emergency Diesel Generator Sets

    • 摘要: 针对应急柴油机(emergency diesel generator, EDG)组调速系统整机试验成本高、测试效率较低、故障难复现等问题,基于硬件在环(hardware-in-the-loop, HIL)仿真技术设计了一套测试平台。该平台功能组件主要包括用于人机交互的操作台,完成模型开发、测试管理;搭载并运行多型柴油机组数字模型的仿真机,完成实时仿真和信号模拟交互,通过电气设计兼容多型调速系统测试接口;提供电液运行环境的执行器台,完成供油和机械支撑。此外,基于NI TestStand等软件完成自动测试序列开发,便捷完成平台软硬件配置、测试步骤执行、后处理等,提高测试一致性。最后,利用搭建的测试平台完成了两型柴油机的调速系统测试,两型柴油机稳态工况下齿条位移与实机数据相比误差均小于1%,转速稳态波动率小于0.5%,动态试验瞬时调速率小于9%,试验结果满足设计需求。

       

      Abstract: To address the high costs, low testing efficiency, and difficulty in reproducing faults associated with whole-machine testing of emergency diesel generator(EDG) speed control systems, a testing platform was designed based on hardware-in-the-loop(HIL) simulation technology. The platform’s functional components primarily include an operator console for human-machine interaction handling model development and test management, a simulator equipped with and running digital models of multiple diesel generator types, performing real-time simulation and signal simulation interaction, with electrical design compatible with multiple speed control system test interfaces and an actuator bench providing electro-hydraulic operating conditions for fuel supply and mechanical support. Additionally, automated test sequences were developed using software like NI TestStand to streamline platform configuration, test execution, and post-processing, enhancing test consistency. Finally, utilizing the established test platform, speed control system testing was completed for two diesel engine types. Under steady-state operating conditions, the rack displacement errors for both engines compared to actual engine data were less than 1%, the steady-state speed fluctuation rates were less than 0.5%, and the instantaneous speed change rates during dynamic testing were less than 9%. Test results met design requirements.

       

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