大功率低速柴油机测控系统研制
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摘要
随着世界范围内能源危机及环境污染的日趋严重,人们对柴油机节能和排放的要求也日趋严格,对其调节控制提出高精度及多参数的要求。智能化技术是大功率低速船舶柴油机的发展方向,测控系统是开展智能化柴油机研究的重要平台。在深入分析Wartsila智能化柴油机结构和工作原理的基础上,研制了智能化柴油机测控系统。
(1)测控系统技术方案的总体设计:保留原机关键结构和部件作为测控系统的实体执行结构;部署在Compact控制器上的燃油喷射控制仿真模型和排气阀控制仿真模型,与实体执行机构组成智能化柴油机硬件在环仿真系统,较真实地模拟出柴油机负载特性;利用NI PXI和研华工控机硬件载体及LabVIEW软件开发环境,实现测控系统监测报警功能。
(2)智能化柴油机硬件在环仿真系统的建立:通过I/O硬件采集柴油机执行机构信号,利用DMA方式将采集的数据送至Compact控制器,作为模型的输入条件;经仿真模型计算,输出排气阀升程模拟信号等。完成排气阀控制仿真模型的设计和程序开发,并运用“缸平移”法提高了仿真模型精度及实时性。
(3 SSI HUB的设计和曲轴转角信号的解码:依据SSI标准以MAX485芯片为主体搭建SSI HUB硬件电路,从SSI总线上测取曲轴转角信号;并在FPGA中编写曲轴转角信号解码程序,得到实时曲轴转角角度值。
(4)利用CAN总线实现Compact控制器与PXI间的数据交换,并实现监测软件自检功能,以检查各物理设备通讯是否正常。
(5)测控系统报警板的软硬件开发:以AT-S52单片机为中心设计RS-232通讯和继电器驱动外围电路,并开发单片机与工控机串口通讯程序。
As the worldwide energy crisis and environmental pollution become the biggest concerns for us nowadays,the higher standards for fuel efficiency and emission seem more important.Accordingly it requires the higher precision and the more parameter of the control of diesel engine.The development direction of heavy duty low-speed diesel engine is application of technology,and monitoring control system is the important platform of the research for the intelligent diesel engine.Based on the in-depth analysis of structure and working principle of Wartsila intelligent diesel engine,the monitoring control system of intelligent diesel engine is designed.
(1) The whole design of the monitoring control system:Executing agency of the measurement control system is composed of the key component and structure of original machine;The Hardware-in-the-loop(HIL) simulation system is made up of executing agency,fuel injection simulation module and exhaust driving simulation module deployed in the Compact controllers,which simulates load characteristics of diesel engine;Using hardware of NI PXI and Advantech Industrial Computer,and software development environment of LabVIEW,the monitoring and alarming functions.is realization realized.
(2) HIL system for intelligent diesel engine:The signals from executing agency are acquired via I/O hardware and then transferred to the Compact controller by DMA as input-signals for simulation module.After calculation by simulation module,analog signal such as the trend with exhaust valve opening or closing strokes can be produced as output.The design and development of exhaust driving simulation module is completed.The accuracy and real-time capability of the simulation model are improved by the method of "cylinder moving".
(3) The design of SSI HUB and the decoding of crank angle signal:Based on the SSI criteria the hardware circuit of SSI HUB is structured taking the MAX 485 chip as main part,then crank angle signals are acquired from SSI bus.The real-time crank angle is measured throughout the decoding program in the FPGA.
(4) The data exchange between the Compact controller and PXI is implemented by the CAN bus.Self-testing of system is achieved,which check the communications of the physical device.
(5) Hardware and software development of the alarm board:Regarding the AT-S52 single-chip as the central the RS-232 communication and relay driver external circuit are designed.And the serial communication program between single-chip and IPC is developed.
(1)测控系统技术方案的总体设计:保留原机关键结构和部件作为测控系统的实体执行结构;部署在Compact控制器上的燃油喷射控制仿真模型和排气阀控制仿真模型,与实体执行机构组成智能化柴油机硬件在环仿真系统,较真实地模拟出柴油机负载特性;利用NI PXI和研华工控机硬件载体及LabVIEW软件开发环境,实现测控系统监测报警功能。
(2)智能化柴油机硬件在环仿真系统的建立:通过I/O硬件采集柴油机执行机构信号,利用DMA方式将采集的数据送至Compact控制器,作为模型的输入条件;经仿真模型计算,输出排气阀升程模拟信号等。完成排气阀控制仿真模型的设计和程序开发,并运用“缸平移”法提高了仿真模型精度及实时性。
(3 SSI HUB的设计和曲轴转角信号的解码:依据SSI标准以MAX485芯片为主体搭建SSI HUB硬件电路,从SSI总线上测取曲轴转角信号;并在FPGA中编写曲轴转角信号解码程序,得到实时曲轴转角角度值。
(4)利用CAN总线实现Compact控制器与PXI间的数据交换,并实现监测软件自检功能,以检查各物理设备通讯是否正常。
(5)测控系统报警板的软硬件开发:以AT-S52单片机为中心设计RS-232通讯和继电器驱动外围电路,并开发单片机与工控机串口通讯程序。
As the worldwide energy crisis and environmental pollution become the biggest concerns for us nowadays,the higher standards for fuel efficiency and emission seem more important.Accordingly it requires the higher precision and the more parameter of the control of diesel engine.The development direction of heavy duty low-speed diesel engine is application of technology,and monitoring control system is the important platform of the research for the intelligent diesel engine.Based on the in-depth analysis of structure and working principle of Wartsila intelligent diesel engine,the monitoring control system of intelligent diesel engine is designed.
(1) The whole design of the monitoring control system:Executing agency of the measurement control system is composed of the key component and structure of original machine;The Hardware-in-the-loop(HIL) simulation system is made up of executing agency,fuel injection simulation module and exhaust driving simulation module deployed in the Compact controllers,which simulates load characteristics of diesel engine;Using hardware of NI PXI and Advantech Industrial Computer,and software development environment of LabVIEW,the monitoring and alarming functions.is realization realized.
(2) HIL system for intelligent diesel engine:The signals from executing agency are acquired via I/O hardware and then transferred to the Compact controller by DMA as input-signals for simulation module.After calculation by simulation module,analog signal such as the trend with exhaust valve opening or closing strokes can be produced as output.The design and development of exhaust driving simulation module is completed.The accuracy and real-time capability of the simulation model are improved by the method of "cylinder moving".
(3) The design of SSI HUB and the decoding of crank angle signal:Based on the SSI criteria the hardware circuit of SSI HUB is structured taking the MAX 485 chip as main part,then crank angle signals are acquired from SSI bus.The real-time crank angle is measured throughout the decoding program in the FPGA.
(4) The data exchange between the Compact controller and PXI is implemented by the CAN bus.Self-testing of system is achieved,which check the communications of the physical device.
(5) Hardware and software development of the alarm board:Regarding the AT-S52 single-chip as the central the RS-232 communication and relay driver external circuit are designed.And the serial communication program between single-chip and IPC is developed.
引文
[1]Emission Reduction Technology for Future Heavy Duty Combustion Engines[J],CIMAC DAY 1999
[2]P.Sorensen and P.s.Pedersen.The intelligent engine-design status and service experience[J].23~(rd)CIMA Word Congress on Combustion Engine Technology,2001
[3]Dr.R.W.Jorach,H.DoPPIer,H.Ressel and Dr.W.Seheibe.Common rail applications for medium speed engines the answer from the fuel injection system supplier on the customer demands[J].23~(rd)CIMA Word Congress on Combustion Engine Technology,2001
[4]李煜辉,中压共轨柴油机电控系统控制器设计与研究.武汉理工大学博士学位论文[D].2003
[5]王尚勇,杨青.柴油机电子控制技术.机械工业出版社[M].2005
[6]唐开元,欧阳光耀.高等内燃机学.国防工业出版社[M].2008
[7]张艳.高压共轨柴油机电控系统的研究,北京交通大学硕士学位论文[D].2006
[8]黄茂杨.柴油机高压共轨燃油喷射系统高速电磁阀结构与控制参数优化及其特性测试系统的研制[D],东南大学博士学位论文.2005
[9]杨阳.高压共轨柴油机电控系统分析与研究[D],上海交通大学硕士学位论文,2007
[10]肖文雍,杨林,梁峰.GD-1高压共轨式电控柴油机燃油喷射压力控制策略的研究[J].内燃机学报.2004(3):235-239
[11]杨建国,朱国伟,崔可润等.柴油机电子控制实验装置的开发与研究.交通部科技成果鉴定书(交科鉴字2001第045号),2001.9
[12]沈晓明.柴油机蓄压共轨式电控泵喷嘴系统的开发研究[D].北京理工大学博士学位论文,1997
[13]崔可润.中压共轨电控柴油机可变气门系统的研究[D].武汉理工大学博士论文,2002
[14]陈勤学,崔可润,朱国伟.中压共轨电控柴油机可变气门系统的研制[J].热科学与技术,2002,(2):123-127
[15]陈勤学,崔可润,朱国伟.中压共轨柴油机电控可变气门系统的实验研究[J].内燃机工程,2002,23(4):1-5
[16]冼伟伦,余天明.船用电控共轨型柴油机的最新技术特点和管理[J].船舶,2006,(6):38-40
[17]王洪峰.船用智能化柴油机热力参数监测与诊断技术研究[D].武汉理工大学硕士论文,2008
[18]张坚,李善从.船用低速大功率智能型柴油机的发展[J].船舶与设备,2006,1
[19]王宏明,谢荣.Sulzer RT-Flex型柴油机的共轨技术[J].天津航海,2004,(2):17-19
[20]林晨阳,陈超凡.MAN-B&WS60ME-C智能型共轨柴油机[J].船海技术,2002,4
[21]Wartsila Corporation.Wartsila low speed engines continuing progress.2005,12
[22]Wartsila Corporation.Wartsila RT-Flex主机介绍.2008,5
[23]杜淼,新型智能电喷主机Sulzer RT_flex机[J].船电技术,2004,(5):45-47
[24]Wartsila Corporation.Wartsila Switzerland Ltd Engine Control System WECS-9520,2005
[25]Wartsila Corporation.Waartsila Switzerland Ltd Engine Selection and Project Manual,2003
[26]刘镇宇,聂延生,马会普.船用共轨柴油机的控制方法[J].大连海事大学学报,2006,3Z(2):49-51
[27]吴桂涛,任旭东.世界最大的智能型共轨柴油机-苏尔寿RT-Fle~[J].航海技术,2001,5
[28]Kaspar A,John M.Common Rail at Sea:The Sulzer RT-Flex engine[R].Copenhagen:The Motor Ship Marine Propulsion Conference,2002
[29]National Instruments.NI CompactRIO可重新配置的控制和采集系统技术白皮书[EB/ON],https://lumen.ni.com/nicif/zhs/WPCOMPACTRIO/content.xhtml,2009.
[30]王宏明,谢荣.Sulzer RT-Flex型柴油机的共轨技术[J].天津航海,2004,(2):17-19
[31]Kaspar A.Experience with Sulzer Common-Rail Engines[R].Wartsilia Corporation,2003
[32]李彬轩,柴油机电控单元硬件在环仿真系统的设计及其相关研究[D].浙江大学博士学位论文,2001
[33]唐航波,龚元明,谭文春,卓斌.柴油机高压共轨ECU硬件在环仿真系统硬件设计[J].车用发动机,2005,(1):24-28
[34]NI Instruments.NI CompactRIO平台配置指导及用户方案.NI Instruments Corporation,2007
[35]Robert Zeidman,Designing with FPGAs and CPLDs[M].Published by CMP Books,2002
[36]National Instruments.LabVIEW FPGA Module 8.2 Help.National Instruments Inc,2006
[37]汤同垒.RCV420 I/V转换 电路的几种典型应用[J].自动化仪表.1996,8
[38]安治永,苏长兵,李应红.XTR105、RCV420在温度检测系统中的应用[J].传感器世界,2005,5
[39]高翠云,奖朝晖.利用MAX291实现抗混跌滤波[J].现代电子技术,2004,10
[40]张子蓬,王淑青,刘辉.接口的绝对值角度编码器值的读出方法研究[J].工业控制计算机,2005,18(12):4-5
[41]戴蓉,王高鹏,齐向华.SSI-485转换器的研究与应用[J].水利水文自动化.2008,6
[42]靳红涛,赵勇进,陈朝基,等.一种SSI接口光电编码器数据并行采集设计方法[J].电子技术,2008
[43]Maxim Integrated Products.Max485 datasheet.Maxim Integrated Products Inc,2003
[44]姜丹娜,张付军,赵长禄.用“缸平移”法提高柴油机模型实时性的方法研究[J].内燃机工程[J],2006,(27):43-45
[45]NI Instruments.cRIO Fundamentals Couse Manual.National Instruments Inc,2003,07
[46]陈锡辉,张银鸿.LabVIEW 8.20程序设计从入门到精通[M],清华大学出版社,2007
[47]National Instruments,NI-CAN~(TM) Help Part Number 370612F-01-January 2007 Edition.2007,National Instruments Corporation
[48]CAN Specification Version 2.0[S].Robert Bosch GmbH,1992
[49]石磊,杨建国.电控中压共轨柴油机综合实验台监控系统开发[D].武汉理工大学硕士学位论文,2005,11
[50]李朝青.PC机及单片机数据通信技术[M],北京航空航天大学出版社,2000,12
[51]汪至刚,杨建国.MAN与Sulezer柴油机电控燃油系统分析[J].中国内燃机学会大功率柴油机分会五届二次学术年会论文集.2004
[52]冼伟论,余天明.船用柴油机电控共轨新技术的特点[J].船舶.2006,6
[53]王征.基于PXI和CRIO的高压共轨燃油喷射系统测控平台.基于计算机的测试测量和自动化应用方案[R].National Instruments Corporation.2008
[2]P.Sorensen and P.s.Pedersen.The intelligent engine-design status and service experience[J].23~(rd)CIMA Word Congress on Combustion Engine Technology,2001
[3]Dr.R.W.Jorach,H.DoPPIer,H.Ressel and Dr.W.Seheibe.Common rail applications for medium speed engines the answer from the fuel injection system supplier on the customer demands[J].23~(rd)CIMA Word Congress on Combustion Engine Technology,2001
[4]李煜辉,中压共轨柴油机电控系统控制器设计与研究.武汉理工大学博士学位论文[D].2003
[5]王尚勇,杨青.柴油机电子控制技术.机械工业出版社[M].2005
[6]唐开元,欧阳光耀.高等内燃机学.国防工业出版社[M].2008
[7]张艳.高压共轨柴油机电控系统的研究,北京交通大学硕士学位论文[D].2006
[8]黄茂杨.柴油机高压共轨燃油喷射系统高速电磁阀结构与控制参数优化及其特性测试系统的研制[D],东南大学博士学位论文.2005
[9]杨阳.高压共轨柴油机电控系统分析与研究[D],上海交通大学硕士学位论文,2007
[10]肖文雍,杨林,梁峰.GD-1高压共轨式电控柴油机燃油喷射压力控制策略的研究[J].内燃机学报.2004(3):235-239
[11]杨建国,朱国伟,崔可润等.柴油机电子控制实验装置的开发与研究.交通部科技成果鉴定书(交科鉴字2001第045号),2001.9
[12]沈晓明.柴油机蓄压共轨式电控泵喷嘴系统的开发研究[D].北京理工大学博士学位论文,1997
[13]崔可润.中压共轨电控柴油机可变气门系统的研究[D].武汉理工大学博士论文,2002
[14]陈勤学,崔可润,朱国伟.中压共轨电控柴油机可变气门系统的研制[J].热科学与技术,2002,(2):123-127
[15]陈勤学,崔可润,朱国伟.中压共轨柴油机电控可变气门系统的实验研究[J].内燃机工程,2002,23(4):1-5
[16]冼伟伦,余天明.船用电控共轨型柴油机的最新技术特点和管理[J].船舶,2006,(6):38-40
[17]王洪峰.船用智能化柴油机热力参数监测与诊断技术研究[D].武汉理工大学硕士论文,2008
[18]张坚,李善从.船用低速大功率智能型柴油机的发展[J].船舶与设备,2006,1
[19]王宏明,谢荣.Sulzer RT-Flex型柴油机的共轨技术[J].天津航海,2004,(2):17-19
[20]林晨阳,陈超凡.MAN-B&WS60ME-C智能型共轨柴油机[J].船海技术,2002,4
[21]Wartsila Corporation.Wartsila low speed engines continuing progress.2005,12
[22]Wartsila Corporation.Wartsila RT-Flex主机介绍.2008,5
[23]杜淼,新型智能电喷主机Sulzer RT_flex机[J].船电技术,2004,(5):45-47
[24]Wartsila Corporation.Wartsila Switzerland Ltd Engine Control System WECS-9520,2005
[25]Wartsila Corporation.Waartsila Switzerland Ltd Engine Selection and Project Manual,2003
[26]刘镇宇,聂延生,马会普.船用共轨柴油机的控制方法[J].大连海事大学学报,2006,3Z(2):49-51
[27]吴桂涛,任旭东.世界最大的智能型共轨柴油机-苏尔寿RT-Fle~[J].航海技术,2001,5
[28]Kaspar A,John M.Common Rail at Sea:The Sulzer RT-Flex engine[R].Copenhagen:The Motor Ship Marine Propulsion Conference,2002
[29]National Instruments.NI CompactRIO可重新配置的控制和采集系统技术白皮书[EB/ON],https://lumen.ni.com/nicif/zhs/WPCOMPACTRIO/content.xhtml,2009.
[30]王宏明,谢荣.Sulzer RT-Flex型柴油机的共轨技术[J].天津航海,2004,(2):17-19
[31]Kaspar A.Experience with Sulzer Common-Rail Engines[R].Wartsilia Corporation,2003
[32]李彬轩,柴油机电控单元硬件在环仿真系统的设计及其相关研究[D].浙江大学博士学位论文,2001
[33]唐航波,龚元明,谭文春,卓斌.柴油机高压共轨ECU硬件在环仿真系统硬件设计[J].车用发动机,2005,(1):24-28
[34]NI Instruments.NI CompactRIO平台配置指导及用户方案.NI Instruments Corporation,2007
[35]Robert Zeidman,Designing with FPGAs and CPLDs[M].Published by CMP Books,2002
[36]National Instruments.LabVIEW FPGA Module 8.2 Help.National Instruments Inc,2006
[37]汤同垒.RCV420 I/V转换 电路的几种典型应用[J].自动化仪表.1996,8
[38]安治永,苏长兵,李应红.XTR105、RCV420在温度检测系统中的应用[J].传感器世界,2005,5
[39]高翠云,奖朝晖.利用MAX291实现抗混跌滤波[J].现代电子技术,2004,10
[40]张子蓬,王淑青,刘辉.接口的绝对值角度编码器值的读出方法研究[J].工业控制计算机,2005,18(12):4-5
[41]戴蓉,王高鹏,齐向华.SSI-485转换器的研究与应用[J].水利水文自动化.2008,6
[42]靳红涛,赵勇进,陈朝基,等.一种SSI接口光电编码器数据并行采集设计方法[J].电子技术,2008
[43]Maxim Integrated Products.Max485 datasheet.Maxim Integrated Products Inc,2003
[44]姜丹娜,张付军,赵长禄.用“缸平移”法提高柴油机模型实时性的方法研究[J].内燃机工程[J],2006,(27):43-45
[45]NI Instruments.cRIO Fundamentals Couse Manual.National Instruments Inc,2003,07
[46]陈锡辉,张银鸿.LabVIEW 8.20程序设计从入门到精通[M],清华大学出版社,2007
[47]National Instruments,NI-CAN~(TM) Help Part Number 370612F-01-January 2007 Edition.2007,National Instruments Corporation
[48]CAN Specification Version 2.0[S].Robert Bosch GmbH,1992
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