CN115032479A - Energy recycling system and method for electronic control single machine aging test - Google Patents
Energy recycling system and method for electronic control single machine aging test Download PDFInfo
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Abstract
The invention provides an energy recycling system and method for an electronic control single machine aging test, and solves the technical problem that the existing test energy cannot be effectively utilized. The system comprises: the super capacitor bank forms controlled energy storage and provides adaptive working power and/or working voltage for an electric control single machine of an aging test; the energy recovery module is used for forming controlled energy conversion, simulating the actual load characteristic in an electric control single machine burn-in test, and converting the test power in the burn-in test process to form recovered power output; the braking unit is used for forming peak power release in the process of converging the recovered power to the super capacitor bank and residual power absorption after the burn-in test is stopped; and the energy management unit is used for monitoring the charging and discharging state of the super capacitor bank and forming a charging and discharging time sequence of the super capacitor bank according to the aging test procedure and the charging and discharging state. Batch electric control single machine aging test process is scheduled comprehensively, time interval is fully utilized for circular work, the capacity of the whole set of test system is reduced, and test energy waste is avoided.
Description
Technical Field
The invention relates to the technical field of burn-in tests, in particular to an energy recycling system and method for an electric control single machine burn-in test.
Background
In the prior art, burn-in testing is a screening method widely used in the electronics manufacturing, military and aerospace industries to reduce or eliminate early product failure. For the aging test of the electric control single machine, the method usually applies proper environmental stress and electric stress excitation to the single machine, simulates the practical application working condition for a long time, and aims to expose the defects of the manufacturing process, components and the like as soon as possible and eliminate or repair the defects.
Because a large number of controlled objects such as hydraulic electric control valves exist in an actual system, most of the electric control single machines have a multi-channel power output function. For the aging test of the power output type electric control single machine, a high-power armored resistor or an electronic load is generally adopted as a single machine test tool in the industry at present, and different steady-state load working conditions can be well simulated by selecting power resistors with different resistance values. But the essence is to convert electric energy into heat energy for dissipation, and considerable electric energy is consumed in long-time aging test or identification test. With the well-blowout type increase of the demand of the current electric control single machine, the waste of electric energy is more serious.
Disclosure of Invention
In view of the above problems, embodiments of the present invention provide an energy recycling system and method for an electrical control single machine burn-in test, which solve the technical problem that the existing test energy cannot be effectively utilized.
The energy recycling system for the electronic control single machine burn-in test of the embodiment of the invention comprises:
the super capacitor bank is used for forming controlled energy storage and providing adaptive working power and/or working voltage for an electric control single machine of the burn-in test;
the energy recovery module is used for forming controlled energy conversion, simulating the actual load characteristic in the burn-in test of the electric control single machine, and converting the test power in the burn-in test process to form recovered power output;
the braking unit is used for forming peak power release in the process of converging the recovered power to the super capacitor bank and residual power absorption after the burn-in test is stopped;
and the energy management unit is used for monitoring the charging and discharging state of the super capacitor bank, forming a charging and discharging time sequence of the super capacitor bank according to the aging test procedure and the charging and discharging state, and performing charging and discharging management on the super capacitor bank.
In an embodiment of the present invention, the super capacitor bank includes a plurality of capacitor modules.
In an embodiment of the invention, the energy recovery module comprises a power-controllable DC-DC converter.
In an embodiment of the present invention, the energy management unit includes:
an electrical path switching matrix for controlling the electrical path switching matrix to provide a controlled switched electrical path between connected active devices;
and the data processor is used for controlling the storage, output and recovery of the electric power according to the aging test rule.
In one embodiment of the present invention, the energy management unit establishes controlled electrical connection with an external power source through the electrical path switching matrix, establishes controlled electrical connection with each capacitor module in the super capacitor bank through the electrical path switching matrix, and establishes controlled electrical connection with each electrically controlled single machine through the electrical path switching matrix; establishing a controlled electrical connection with the brake unit through the electrical path switching matrix; the power output port of each electric control single machine is electrically connected with the power input port of the DC-DC converter; a power output port of the DC-DC converter establishes a controlled electrical connection with the electrical path switching matrix of the energy management unit.
The energy recycling method for the electric control single machine aging test of the embodiment of the invention comprises the following steps:
establishing an electric connection branch between a mains supply and a super capacitor bank to form initial charging and voltage stabilization of a capacitor module in the super capacitor bank;
controlling the super capacitor bank to output electric power signals to the corresponding electric control single machine to drive the electric control single machine according to the aging test procedure of the electric control single machine, and starting an aging test;
according to an electric control single machine burn-in test procedure, control data are formed in a burn-in test to drive an energy recovery module to simulate actual load characteristics;
forming instantaneous recovery power according to the test power output by each energy recovery module, and forming an electric connection bypass between the energy recovery modules and the brake unit according to whether the instantaneous recovery power reaches a peak power threshold value;
and forming an electric connection path between the energy recovery module and the super capacitor group to charge the super capacitor group in order.
In an embodiment of the present invention, the forming of the test procedure of the electronic control single machine aging includes:
determining continuous input power expectation of each electric control single machine in the aging test process;
forming a unit time slot of a burn-in test, and forming a test channel of the burn-in test through continuous unit time slots;
determining data in the channel of the electric control single machine for the aging test in each test channel according to the expected superposition power of the electric control single machine and the stable output power peak value of the super capacitor bank;
and establishing an aging period test procedure according to the data in the electric control single machine channel and the test channel.
In an embodiment of the present invention, the forming of the test procedure of the electronic control single machine aging includes:
determining the number of the electric control single machines of the aging test;
determining the test step of the aging test;
determining the number of the synchronous electric control single machines in the test step;
and forming an interleaving test rule among the synchronous electric control single machines in the aging test.
The energy recycling system for the electric control single machine aging test of the embodiment of the invention comprises:
a memory for storing program codes of a control process in the above energy recycling method;
a processor for executing the program code.
In an embodiment of the present invention, the processor is a digital signal processor, a field programmable gate array, a system board, or a PLC.
The energy recycling system and method for the electric control single machine burn-in test of the embodiment of the invention form a circuit route for recycling and reusing electric energy power of the electric control single machine test in the processes of energy storage, test and consumption in the burn-in test by fully utilizing a mature circuit switching matrix technology, and provide a circuit control basis for orderly allocating the electric energy power of the test. Batch and batch electronic control single machine aging test processes are scheduled comprehensively, time intervals are fully utilized for cyclic work, the capacity of the whole set of test system is reduced, and test energy waste is avoided.
Drawings
Fig. 1 is a schematic diagram of an energy recycling system for an electrically controlled single-machine burn-in test according to an embodiment of the present invention.
Fig. 2 is a schematic flow chart illustrating an energy recycling method for an electrically controlled single-machine burn-in test according to an embodiment of the present invention.
Fig. 3 is a schematic diagram of an interval test in the energy recycling method of the electrically controlled single-machine burn-in test according to an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention clearer and more obvious, the present invention is further described below with reference to the accompanying drawings and the detailed description. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be obtained by a person skilled in the art without inventive step based on the embodiments of the present invention, are within the scope of protection of the present invention.
An energy recycling system for an electrically controlled single machine aging test according to an embodiment of the present invention is shown in fig. 1. In fig. 1, the present embodiment includes:
and the super capacitor bank 10 is used for forming controlled energy storage and providing adaptive working power and/or working voltage for the electric control single machine of the burn-in test.
The super capacitor bank is formed by combining a plurality of capacitor modules. The capacitor module stores electric energy at an interface of the electronic conductor and the electrolyte solution, has high charging and discharging speed and large charging and discharging current, is more suitable for an energy recycling system needing quick charging and discharging compared with a battery, and is mainly used for storing and providing stable electric energy. When the system works, the output voltage of the capacitor module is basically consistent with the supply voltage of the connected electric control single machine. The charging and discharging of the defining capacitor module can be formed by sophisticated control techniques.
And the energy recovery module 20 is used for forming controlled energy conversion, simulating the actual load characteristic in the aging test of the electric control single machine, and converting the test power in the aging test process to form recovered power output.
The energy recovery module mainly comprises a power-controllable DC-DC converter. The input current and the input power of the energy recovery module are adjusted according to the selected mode, the load characteristic of a controlled load object is simulated through the DC-DC converter, for example, the load current is gradually increased according to the characteristic of a controlled valve core of a load hydraulic electric control valve of an electric control single machine, and the impedance characteristic of an actual load controlled valve core is simulated. The energy recovery module in the whole process can rapidly adjust the input power and the output voltage according to the control requirements of the energy management unit, the coordinated operation requirements of the whole system are met, the aging test is carried out on the corresponding electric control single machine, meanwhile, the output power of the single machine is efficiently recovered, the recovered power in the form of electric energy is output in high quality, and the consumption in the form of impedance thermal power is avoided.
And the brake unit 30 is used for forming peak power release in the process of converging the recovered power to the super capacitor bank and residual power absorption after the burn-in test is stopped.
The randomly output recovery power of the energy recovery modules is converged and recovered to easily form a peak power signal, and the braking unit is required to dissipate and convert peak energy which cannot be effectively recovered so as to ensure the safe and stable operation of the system. When the whole set of system needs to be shut down for a long time, residual energy in the super capacitor bank can be consumed after the system is shut down, the service life of the super capacitor bank is prolonged, and the risk of accidental electric shock and injury of personnel is reduced.
And the energy management unit 40 is used for monitoring the charging and discharging state of the super capacitor bank, forming a charging and discharging time sequence of the super capacitor bank according to the aging test specification and the charging and discharging state, and performing charging and discharging management on the super capacitor bank.
The energy management unit is responsible for managing energy flow and control information in the process of the electric control single machine aging test. The energy management unit comprises a controlled electric path switching matrix which is built by mature technical means such as an IGBT module, a silicon controlled power device, an operational amplifier and the like, and the controlled electric path switching matrix provides a controlled switching electric path for the connected active devices or devices. The controlled electrical path switching matrix forms a plurality of power signal input interfaces and output interfaces for the capacitor modules in the ultracapacitor bank. The energy management unit is connected with an external power supply (such as commercial power) through the electric path switching matrix, provides energy required by initial operation for the energy recycling system, realizes initial charging of the capacitor module, and supplements electric energy converted into internal energy dissipation due to transmission and conversion loss in time according to the charging and discharging state of the capacitor module. Meanwhile, the energy management unit redistributes the electric energy power signals recovered from the energy recovery module according to the working state of each super capacitor group, and the working time sequence of each group of super capacitors is properly changed by switching the electric paths through the controlled electric path switching matrix, so that the capacitor modules are sequentially charged as required. And the energy management unit is responsible for switching and distributing the electric energy in the super capacitor bank to each tested single machine again according to the aging test rule requirement to complete the aging test process, so as to form the charging and discharging health management of the super capacitor bank. The energy management unit can enable the whole set of system to realize balanced and stable operation under the support of multiple loads and multiple groups of energy sources under overall regulation and control.
The energy management unit comprises a data processor and a control unit, wherein the data processor is used for controlling the storage, the output and the recovery of electric power according to the aging test procedure, and is specifically embodied in that the route switching control is carried out on an electric path switching matrix to form an electric connection route among a super capacitor bank, an electric control single machine, an energy recovery module and a braking unit; and forming analog control of actual load characteristics according to a burn-in test procedure, and particularly realizing dynamic control of voltage conversion parameters of the DC-DC converter.
As shown in fig. 1, in the present embodiment, the energy management unit 40 includes an electrical path switching matrix, and the energy management unit 40 establishes controlled electrical connection with an external power source through the electrical path switching matrix, respectively establishes controlled electrical connection with each capacitor module in the supercapacitor bank 10 through the electrical path switching matrix, and respectively establishes controlled electrical connection with each electrically controlled single machine through the electrical path switching matrix; establishing controlled electrical connection with the brake unit through the electrical path switching matrix; the energy recovery module 20 comprises a DC-DC converter, and the power output port of each electric control single machine is electrically connected with the power input port of the DC-DC converter of the energy recovery module 20; the power output ports of the DC-DC converter establish controlled electrical connections with the electrical path switching matrix of the energy management unit 40.
An electrical path switching matrix formed by mature power semiconductor technology or series-parallel circuit relay control technology can form a controlled transmission route of electrical power signals between connected electrical devices. The electric connection determining time sequence can be formed according to a control rule or a control strategy, and the electric connection topological structure between the capacitor module and the electric control single machine-DC-DC converter is determined aiming at the electric control single machine aging test process.
The energy recycling system for the electric control single machine burn-in test of the embodiment of the invention forms a circuit route for recycling and reusing electric energy power of the electric control single machine test in the process of energy storage, test and consumption in the burn-in test by fully utilizing a mature circuit switching matrix technology, and provides a circuit control basis for orderly allocating the electric energy power of the test. Batch and batch electronic control single machine burn-in test process can realize overall scheduling, the burn-in test time interval is fully utilized to circularly work, the capacity of the whole set of test system is reduced, and the charging waste of the system is further reduced.
The energy recycling method of the electric control single machine aging test of the embodiment of the invention is shown in fig. 2. In fig. 2, the present embodiment includes:
step 110: establishing an electric connection branch between a mains supply and a super capacitor bank to form initial charging and voltage stabilization of a capacitor module in the super capacitor bank;
the capacitor modules included in the supercapacitor bank may form an initial charging process of sequential charging and parallel charging according to a controlled electrical connection channel topology provided by an electrical path switching matrix included in the energy management unit. The energy management unit can control the commercial power conversion power and the electric connection channel to perform voltage stabilization charging on the determined capacitor modules in the long-time test process according to the monitoring feedback data of the voltage of each capacitor module so as to maintain the storage of the basic threshold voltage and the basic power of the super capacitor. Those skilled in the art will appreciate that the electrical path switching matrix included in the supercapacitor bank can form a combined transformation of the series-parallel topology connection structure of the capacitor modules through circuit switching, and form a power transformation of a single output port of the supercapacitor bank.
Step 120: controlling the super capacitor bank to output electric power signals to the corresponding electric control single machine to drive the electric control single machine according to the aging test procedure of the electric control single machine, and starting an aging test;
the energy management unit includes an electrical path switching matrix providing controlled electrical connections formed according to the number of electrically controlled individual units, controlled to output specification rated dynamic electrical power signals.
Step 130: according to an electric control single machine burn-in test procedure, control data are formed in a burn-in test to drive an energy recovery module to simulate the actual load characteristic;
according to the test process of the electric control single machine aging test procedure, a processor included in the energy management unit forms control data to adjust the input mode of a DC-DC converter included in the energy recovery module, and the input mode comprises the adjustment of input current, input power and the like, so that continuous simulation of actual load characteristics is formed.
Step 140: forming instantaneous recovery power according to the test power output by each energy recovery module, and forming an electric connection bypass between the energy recovery modules and the brake unit according to whether the instantaneous recovery power reaches a peak power threshold value;
the measurement of the instantaneous recovery power is based on a power signal or a voltage or current signal collected on an equivalent parallel node at the output end of the energy recovery module. And when the instantaneous recovery power reaches the peak power threshold value, triggering the electric path switching matrix included by the energy management unit to switch to form an electric connection bypass between the energy recovery module and the brake unit.
Step 150: and forming an electric connection path between the energy recovery module and the super capacitor group to charge the super capacitor group in order.
The electric path switching matrix included by the super capacitor bank is controlled to form an electric connection path between each energy recovery module and the super capacitor bank, and the recovery power is formed through a preset charging strategy to orderly charge the capacitor modules included by the super capacitor bank.
The energy recycling method for the electric control single machine burn-in test of the embodiment of the invention recycles the electric energy in the long-time burn-in test and recycles the electric energy again, thereby improving the energy utilization efficiency. In the multi-type small-batch multi-batch production process, the energy recycling method can reasonably distribute the test time of each type and batch of electric control single machines, the whole energy recycling efficiency can be further improved, and the electric energy waste is obviously reduced.
The batch burn-in test of the electric control single machine in the energy recycling process of the electric control single machine burn-in test of the embodiment of the invention is shown in fig. 3. With reference to fig. 2, the process of forming the aging test procedure of the electronic control unit in the energy recycling method of the embodiment includes:
step 121: determining continuous input power expectation of each electric control single machine in the aging test process;
the electric control single machine aging test process has certainty, has corresponding continuous input power expectation, and can be calibrated by adopting an input power curve.
Step 122: forming a unit time slot of a burn-in test, and forming a test channel of the burn-in test through continuous unit time slots;
and determining the time length of the test period according to the past experience data of the aging test, and determining the basic time length of the divided time in the test period as the unit time slot according to the intensity of the change of the input power curve. Different numbers of continuous unit time slots form targeted time segments, and unified power signal control is carried out aiming at the time segments.
Step 123: determining data in the channel of the electric control single machine for the aging test in each test channel according to the expected superposition power of the electric control single machine and the stable output power peak value of the super capacitor bank;
the peak value of the stable output power of the supercapacitor bank is related to the capacity configuration and the charging and discharging efficiency of the supercapacitor bank of the energy recycling system in the embodiment. And (3) performing time sequence translation on the input power of each electric control motor according to the continuous input power expectation of each electric control motor, so that the input power expectation of the electric control motors after translation is superimposed in the same test channel to form superimposed power expectation. The electronic control single machine combination which can be overlapped in the test channel can be formed by adjusting the translation on the expected time sequence of the input power of different electronic control single machines, and the power input requirement after the single machine combination is met and accords with the peak value range of the stable output power of the super capacitor bank. Further, according to the translation information on the expected time sequence of the input power and the number of the electrically controlled single machines in each test channel, the method can be formed
The expected superposition of the input power of enemy and different electric control single machines can form the data (specifically determining the single machine) in the electric control single machine channel which accords with the stable output power peak value range of the super capacitor bank in each test channel.
Step 124: and establishing an aging period test rule according to the data in the channel of the electric control single machine and the test channel.
The test channels form a batch electric control single machine aging period, data in the channels form a translation time sequence which determines the electric control single machines in the test channels and corresponds to continuous input power expectation, input power control data of the electric control single machines in each electric control single machine channel are determined according to the continuous input power expectation of the electric control single machines, and then a whole aging period test rule is formed.
The energy recycling method for the aging test of the electric control single machine fully utilizes the aging test time interval to circularly work, and different channels of the same single machine circularly work in sequence, so that the working point of the system tends to be stable when the aging test is carried out on different electric control single machines, the capacity of the whole set of test system is reduced, and the charging waste of the system can be further reduced.
As shown in fig. 2, in an embodiment of the present invention, a process of forming an electrically controlled single machine aging test procedure in the energy recycling method of this embodiment includes:
step 125: determining the number of the electric control single machines of the aging test;
and determining the quantity of the same batch of electric control single machines with the same model.
Step 126: determining a test step of an aging test;
the test steps and the test period duration of the same batch of the electric control single machines are basically the same.
Step 127: determining the number of the synchronous electric control single machines in the test step;
the synchronous electric control single machines refer to the number of the electric control single machines with synchronous and consistent test steps, the electric control single machines can be divided into groups in the same batch of electric control single machines, and the test steps of each group of electric control single machines are synchronous and consistent.
Step 128: and forming a staggered test procedure among the synchronous electric control single machines in the aging test.
The test steps of the synchronous electric control single machine are consistent, and the test steps comprise input power, aging duration and load simulation parameters in the same step. Different synchronous electric control single machines execute different test steps, test steps or osmund sequence steps, or interval steps. And the synchronous electric control single machines form the staggered control of the test steps.
The energy recycling method for the electric control single machine burn-in test can optimize and adjust the working mode of each station according to the type of the batch production test, can carry out production of each batch in a staggered way, can further improve the energy recycling efficiency, and can obviously reduce electric energy waste.
The energy recycling system for the electric control single machine aging test of the embodiment of the invention comprises:
the memory is used for storing program codes of the control process in the energy recycling method of the electric control single machine aging test in the embodiment;
and the processor is used for executing the program codes of the control process in the energy recycling method of the electric control single machine aging test in the embodiment.
The processor may employ the data processor in the above embodiments.
The data processor may be a dsp (digital Signal processor), an FPGA (Field-Programmable Gate Array), an mcu (microcontroller unit) system board, an soc (system on a chip) system board, or a plc (Programmable Logic controller) minimum system including I/O.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention should be subject to the protection scope of the claims.
Claims (10)
1. The utility model provides an energy recuperation system of recycling of automatically controlled unit burn-in test which characterized in that includes:
the super capacitor bank is used for forming controlled energy storage and providing adaptive working power and/or working voltage for an electric control single machine of the burn-in test;
the energy recovery module is used for forming controlled energy conversion, simulating the actual load characteristic in the burn-in test of the electric control single machine, and converting the test power in the burn-in test process to form recovered power output;
the braking unit is used for forming peak power release in the process of converging the recovered power to the super capacitor bank and residual power absorption after the burn-in test is stopped;
and the energy management unit is used for monitoring the charging and discharging state of the super capacitor bank, forming a charging and discharging time sequence of the super capacitor bank according to the aging test procedure and the charging and discharging state, and performing charging and discharging management on the super capacitor bank.
2. The energy recovery and reuse system for electric controlled stand-alone burn-in test of claim 1, wherein said super capacitor bank comprises a plurality of capacitor modules.
3. The energy recovery and reuse system for electrically controlled stand-alone burn-in tests of claim 2, wherein said energy recovery module comprises a power-controllable DC-DC converter.
4. The energy recovery and reuse system for electric controlled single-machine burn-in test of claim 3, wherein said energy management unit comprises:
an electrical path switching matrix for controlling the electrical path switching matrix to provide a controlled switched electrical path between connected active devices;
and a data processor for controlling the storage, output and recovery of electrical power according to the burn-in test protocol.
5. The energy recycling system for the aging test of the electric control single machine as claimed in claim 4, wherein the energy management unit establishes controlled electrical connection with the external power source through the electrical path switching matrix, respectively establishes controlled electrical connection with each capacitor module in the super capacitor bank through the electrical path switching matrix, and respectively establishes controlled electrical connection with each electric control single machine through the electrical path switching matrix; establishing a controlled electrical connection with the braking unit through the electrical path switching matrix; the power output port of each electric control single machine is electrically connected with the power input port of the DC-DC converter; a power output port of the DC-DC converter establishes a controlled electrical connection with the electrical path switching matrix of the energy management unit.
6. An energy recycling method for an electric control single machine aging test is characterized by comprising the following steps:
establishing an electric connection branch between a mains supply and a super capacitor bank to form initial charging and voltage stabilization of a capacitor module in the super capacitor bank;
according to the aging test procedure of the electric control single machine, the super capacitor bank is controlled to output electric power signals to the corresponding electric control single machine to drive the electric control single machine, and an aging test is started;
according to an electric control single machine burn-in test procedure, control data are formed in a burn-in test to drive an energy recovery module to simulate the actual load characteristic;
forming instantaneous recovery power according to the test power output by each energy recovery module, and forming an electric connection bypass between the energy recovery module and the brake unit according to whether the instantaneous recovery power reaches a peak power threshold value;
and forming an electric connection path between the energy recovery module and the super capacitor group to charge the super capacitor group in order.
7. The energy recovery and reuse method of electric control single-machine burn-in test of claim 6, wherein the forming of the electric control single-machine burn-in test procedure comprises:
determining continuous input power expectation of each electric control single machine in the aging test process;
forming a unit time slot of a burn-in test, and forming a test channel of the burn-in test through continuous unit time slots;
determining data in the channel of the electric control single machine for the aging test in each test channel according to the expected superposition power of the electric control single machine and the stable output power peak value of the super capacitor bank;
and establishing an aging period test procedure according to the data in the electric control single machine channel and the test channel.
8. The energy recovery and reuse method of electric control single-machine burn-in test of claim 6, wherein the forming of the electric control single-machine burn-in test procedure comprises:
determining the number of the electric control single machines of the aging test;
determining the test step of the aging test;
determining the number of the synchronous electric control single machines in the test step;
and forming a staggered test procedure among the synchronous electric control single machines in the aging test.
9. The utility model provides an energy recuperation system of recycling of automatically controlled unit burn-in test which characterized in that includes:
a memory for storing program codes for controlling processes in the energy recovery and reuse method according to any one of claims 6 to 8;
a processor for executing the program code.
10. The energy recovery and reuse system for electric control stand-alone burn-in test of claim 9, wherein said processor is a digital signal processor, a field programmable gate array, a system board or a PLC.
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