技术领域Technical Field
本发明涉及低高气动试验系统领域，尤其是一种气动设备测控系统。The invention relates to the field of low-height pneumatic test systems, in particular to a pneumatic equipment measurement and control system.
背景技术Background Art
传统的气动设备测控系统，包括上位机、下位机和现场设备，上位机包括新试验段机和电子扫描阀计算机，下位机包括PLC运动控制系统，现场设备包括快速阀、调压阀（主调压阀、引射阀、增引阀）和攻角机构，PLC运动控制系统通过直流电机控制调压阀，利用步进电机控制攻角机构。The traditional pneumatic equipment measurement and control system includes a host computer, a slave computer and field equipment. The host computer includes a new test section machine and an electronic scanning valve computer, the slave computer includes a PLC motion control system, and the field equipment includes a fast valve, a pressure regulating valve (main pressure regulating valve, ejection valve, and injection valve) and an angle of attack mechanism. The PLC motion control system controls the pressure regulating valve through a DC motor and uses a stepper motor to control the angle of attack mechanism.
操作者在上位机配置试验参数，下位机根据试验参数来控制现场设备执行测控试验，电子扫描阀计算机采集试验运行数据，操作者再对比采集的数据和配置的参数，进一步调整试验参数，如此反复，指导采集的运行数据满足要求。The operator configures the test parameters on the upper computer, and the lower computer controls the on-site equipment to perform measurement and control tests based on the test parameters. The electronic scanning valve computer collects the test operation data. The operator then compares the collected data with the configured parameters and further adjusts the test parameters. This process is repeated to ensure that the collected operation data meets the requirements.
该系统需要人工反复调试试验参数，操作较为繁琐，试验周期长，并且需要操作者具备极强的专业能力和经验，人力和时间成本均较高。The system requires repeated manual debugging of test parameters, which is cumbersome to operate and has a long test cycle. It also requires the operator to have strong professional capabilities and experience, and has high manpower and time costs.
另外，该系统在试验时，无论目标马赫数和总压是多少，各阀门均是从零位逐步调整到相应位置，调整过程较为耗时，也会对气体产生较大的浪费。In addition, when the system is tested, no matter what the target Mach number and total pressure are, each valve is gradually adjusted from zero to the corresponding position. The adjustment process is time-consuming and will also result in a large waste of gas.
发明内容Summary of the invention
本发明的发明目的在于：针对上述存在的问题，提供一种改进的气动设备测控系统，以大幅节省试验时调整阀门的时间。The object of the present invention is to provide an improved pneumatic equipment measurement and control system to address the above-mentioned problems, so as to greatly save the time for adjusting valves during testing.
本发明采用的技术方案如下：The technical solution adopted by the present invention is as follows:
一种气动设备测控系统，包括上位机、下位机和现场设备，所述上位机通过网络交换机与所述下位机通信，所述下位机与所述现场设备相连；A pneumatic equipment measurement and control system comprises a host computer, a slave computer and a field device, wherein the host computer communicates with the slave computer through a network switch, and the slave computer is connected to the field device;
所述上位机根据配置的测控参数，生成测控指令下发给所述下位机，所述下位机根据所述测控指令，对所述现场设备执行测控试验，对所述现场设备执行的测控试验包括跨声速试验段和超声速试验段；所述测控参数包括气源压力、目标马赫数、总压和PID参数；所述下位机对所述现场设备的马赫数和总压采用预置阀门开度+阀门开度精调的控制调节方式。The upper computer generates a measurement and control instruction according to the configured measurement and control parameters and sends it to the lower computer. The lower computer performs a measurement and control test on the field equipment according to the measurement and control instruction. The measurement and control test performed on the field equipment includes a transonic test section and a supersonic test section. The measurement and control parameters include air source pressure, target Mach number, total pressure and PID parameters. The lower computer uses a control and adjustment method of preset valve opening + valve opening fine adjustment for the Mach number and total pressure of the field equipment.
综上所述，由于采用了上述技术方案，本发明的有益效果是：In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:
通过预置阀门开度的方式，在试验时直接将各阀门（不同试验模式使用不同的阀门）预置到对应的大致位置，然后再对阀门开度进行精调，不需要从零位逐步调整到要求的位置（传统系统中，该要求的位置需要通过反复调整试验参数，然后观察运行参数才能得到），从而大幅节省试验时调整阀门的时间和工作量，进而可以大幅节省气体量。By presetting the valve opening, each valve (different valves are used in different test modes) is directly preset to the corresponding approximate position during the test, and then the valve opening is fine-tuned. There is no need to gradually adjust from the zero position to the required position (in the traditional system, the required position needs to be obtained by repeatedly adjusting the test parameters and then observing the operating parameters), thereby greatly saving the time and workload of adjusting the valve during the test, and thus significantly saving the amount of gas.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
本发明将通过例子并参照附图的方式说明，其中：The present invention will now be described by way of example with reference to the accompanying drawings, in which:
图1是气动设备测控系统的系统构造图。Figure 1 is a system structure diagram of the pneumatic equipment measurement and control system.
图2、图3分别是跨声速试验段和超声速试验段的试验流程图。Figure 2 and Figure 3 are the test flow charts of the transonic test section and the supersonic test section respectively.
图4是主调压阀阈值开度与气源压力间的关系示意图。FIG. 4 is a schematic diagram showing the relationship between the threshold opening of the main pressure regulating valve and the gas source pressure.
图5是马赫数响应曲线阶段划分示意图，Mr表示实际马赫数，Ms表示目标马赫数，t表示时间。FIG5 is a schematic diagram of the stage division of the Mach number response curve, where Mr represents the actual Mach number, Ms represents the target Mach number, and t represents time.
图6是流场建立时马赫数来回震荡示意图。FIG6 is a schematic diagram of the back-and-forth oscillation of the Mach number when the flow field is established.
具体实施方式DETAILED DESCRIPTION
本说明书中公开的所有特征，或公开的所有方法或过程中的步骤，除了互相排斥的特征和/或步骤以外，均可以以任何方式组合。All features disclosed in this specification, or steps in all methods or processes disclosed, except mutually exclusive features and/or steps, can be combined in any manner.
本说明书（包括任何附加权利要求、摘要）中公开的任一特征，除非特别叙述，均可被其他等效或具有类似目的的替代特征加以替换。即，除非特别叙述，每个特征只是一系列等效或类似特征中的一个例子而已。Any feature disclosed in this specification (including any additional claims and abstract), unless otherwise stated, may be replaced by other alternative features that are equivalent or have similar purposes. That is, unless otherwise stated, each feature is only an example of a series of equivalent or similar features.
气动设备测控系统包括上位机、下位机和现场设备，上位机通过网络交换机与下位机通信，下位机与所述现场设备相连。The pneumatic equipment measurement and control system comprises a host computer, a slave computer and field equipment. The host computer communicates with the slave computer through a network switch, and the slave computer is connected to the field equipment.
上位机根据配置的测控参数，生成测控指令下发给下位机，下位机根据该测控指令，对现场设备执行测控试验，同时下位机还可以采集现场设备的运行参数反馈给上位机。The upper computer generates measurement and control instructions based on the configured measurement and control parameters and sends them to the lower computer. The lower computer performs measurement and control tests on the field equipment based on the measurement and control instructions. At the same time, the lower computer can also collect the operating parameters of the field equipment and feed them back to the upper computer.
上位机配置的测控参数包括吹风模式、现场设备控制参数（如传感器参数、天平参数等）、判稳次数、延时采集时间、PID参数（包括由大到小包括6组PID控制参数，例如第6组为Kp=2.5、Ki=0.1、Kd=5，第1-5组在此基础上以0.1、0.01、0.5为单位依次增加，二次调整时，可重新设定第6组PID控制参数组，以及每一组之间的差值）、目标马赫数、目标阶梯以及总压（各喷管的目标压力）等，这些参数被编码到测控指令中下发给下位机。除此之外，上位机配置的测控参数还包括项目名称、试验段信息、车次号、总压超压阈值、放大器通道参数等。下位机解码测控指令，获得这些测控参数，然后根据这些测控参数执行测控试验。特别的，下位机利用获得的PID参数对现场设备执行测控试验的闭环控制。The measurement and control parameters configured by the host computer include blowing mode, field equipment control parameters (such as sensor parameters, balance parameters, etc.), number of stability judgments, delayed acquisition time, PID parameters (including 6 groups of PID control parameters from large to small, for example, the 6th group is Kp=2.5, Ki=0.1, Kd=5, and the 1st to 5th groups are increased in units of 0.1, 0.01, and 0.5 on this basis. During the secondary adjustment, the 6th group of PID control parameters and the difference between each group can be reset), target Mach number, target step, and total pressure (target pressure of each nozzle), etc. These parameters are encoded into the measurement and control instructions and sent to the lower computer. In addition, the measurement and control parameters configured by the host computer also include project name, test section information, train number, total pressure overpressure threshold, amplifier channel parameters, etc. The lower computer decodes the measurement and control instructions, obtains these measurement and control parameters, and then performs the measurement and control test according to these measurement and control parameters. In particular, the lower computer uses the obtained PID parameters to perform closed-loop control of the measurement and control test on the field equipment.
下位机执行的测控试验包括跨声速自动控制流程、超声速自动控制流程：The measurement and control tests performed by the lower computer include transonic automatic control process and supersonic automatic control process:
跨声速自动控制流程如图2所示，包括：The transonic automatic control process is shown in Figure 2, including:
S101：根据测控参数配置试验参数；S101: configure test parameters according to measurement and control parameters;
S102：预置阀门开度；S102: preset valve opening;
S103：设置攻角为0°，采集初始运行参数；S103: setting the angle of attack to 0° and collecting initial operating parameters;
S104：开启快速阀到指定位置；S104: Open the quick valve to a specified position;
S105：根据目标阶梯循环执行：S105: Execute according to the target ladder cycle:
S106：根据攻角阶梯循环执行：S106: Execute according to the attack angle step cycle:
S107：控制走攻角；S107: Control the attack angle;
S108：根据目标马赫数调节马赫，并根据判稳次数进行循环判稳；S108: adjusting the Mach number according to the target Mach number, and performing a cyclic stability determination according to the number of stability determinations;
S109：根据延时采样时间执行延时，采集当前攻角对应的第一运行参数；S109: Execute delay according to the delay sampling time to collect the first operating parameter corresponding to the current angle of attack;
S110：目标阶梯循环结束，攻角回零；S110: The target step cycle ends and the attack angle returns to zero;
S111：关闭快速阀；S111: Close the quick valve;
S112：延迟预定时间，采集第二运行参数。S112: Delay for a predetermined time and collect a second operating parameter.
超声速自动控制流程与跨声速自动控制流程略有区别，其流程如图3所示，包括：The supersonic automatic control process is slightly different from the transonic automatic control process, and its process is shown in Figure 3, including:
S201：根据测控参数配置试验参数；S201: Configure test parameters according to measurement and control parameters;
S202：预置阀门开度；S202: preset valve opening;
S203：设置攻角为0°，采集初始运行参数；S203: setting the angle of attack to 0° and collecting initial operating parameters;
S204：开启快速阀到指定位置；S204: Open the quick valve to a specified position;
S205：激波通过；S205: shock wave passes;
S206：根据攻角阶梯循环执行：S206: Execute according to the attack angle step cycle:
S207：控制走攻角；S207: Control the attack angle;
S208：根据目标马赫数调节马赫，并根据判稳次数进行循环判稳；S208: adjusting the Mach number according to the target Mach number, and performing a cyclic stability determination according to the number of stability determinations;
S209：根据延时采样时间执行延时，采集当前攻角阶梯对应的第三运行参数；S209: Execute delay according to the delay sampling time to collect the third operating parameter corresponding to the current angle of attack step;
S210：攻角阶梯循环结束，攻角回零；S210: The attack angle step cycle ends and the attack angle returns to zero;
S211：关闭快速阀；S211: Close the quick valve;
S212：延迟预定时间，采集第四运行参数。S212: Delay for a predetermined time and collect a fourth operating parameter.
如图1所示，上位机包括运行管理机、状态监控机、新试验段机和采集处理机。其中运行管理机用于试验流程控制，状态监控机用于整个气动设备状态信息汇总显示并预警。新试验段机与传统气动设备测控系统的相同，采集处理机为在传统气动设备测控系统的电子扫描阀计算机基础上，通过软件开发对其扩能，使其既能采集处理电子扫描阀数据又能采集处理测量系统数据。As shown in Figure 1, the host computer includes an operation management computer, a status monitoring computer, a new test section computer, and an acquisition processor. The operation management computer is used for test process control, and the status monitoring computer is used for the summary display and early warning of the entire pneumatic equipment status information. The new test section computer is the same as the traditional pneumatic equipment measurement and control system. The acquisition processor is based on the electronic scanning valve computer of the traditional pneumatic equipment measurement and control system. Through software development, it is expanded to enable it to collect and process both electronic scanning valve data and measurement system data.
下位机主要包括PLC运动控制系统和PXI测量系统。PXI测量系统负责通过天平传感器等采集现场设备的运行数据，将采集的运行数据传递给PLC运动控制系统，PLC运动控制系统还获取吹风过程中的状态信号，例如阀门位置、模型位置、压力等。PLC运动控制系统需要通过发送来的运行数据（如总压、静压）和获取的状态信号进行马赫数以及总压的闭环控制。PLC运动控制系统主要控制对象有6个（1个快速阀，3个调压阀-主调节阀、引射阀、增引阀，2个攻角机构-全模机构（攻角）、半模机构（转窗）），快速阀由DC24V控制，其它5个控制对象均由电机控制。在传统系统中调压阀由直流电机控制、攻角机构由步进电机控制，为提高控制质量，协调控制模式，本系统将该5个控制对象改成由伺服电机控制，通过伺服驱动器进行驱动。根据5个控制对象负载情况，使用4台5KW伺服电机和1台7KW伺服电机驱动。伺服电机带抱闸和绝对位置编码器，抱闸的作用是机构静止时不因外力而运动，编码器的作用是反馈机构速度、位置信息，实现精确控制。该系统的下位机可以在控制柜上通过触摸屏实施控制，也可以在控制间由上位机实施控制，上位机对控制对象可实施静态运行和动态调节。The lower computer mainly includes PLC motion control system and PXI measurement system. The PXI measurement system is responsible for collecting the operation data of the field equipment through balance sensors and other means, and passing the collected operation data to the PLC motion control system. The PLC motion control system also obtains the status signals during the blowing process, such as valve position, model position, pressure, etc. The PLC motion control system needs to perform closed-loop control of the Mach number and total pressure through the sent operation data (such as total pressure, static pressure) and the obtained status signals. The PLC motion control system mainly controls 6 objects (1 fast valve, 3 pressure regulating valves-main regulating valve, injection valve, and injection valve, 2 angle of attack mechanisms-full mold mechanism (angle of attack), half mold mechanism (rotating window)), the fast valve is controlled by DC24V, and the other 5 control objects are controlled by motors. In the traditional system, the pressure regulating valve is controlled by a DC motor and the angle of attack mechanism is controlled by a stepper motor. In order to improve the control quality and coordinate the control mode, this system changes the 5 control objects to be controlled by a servo motor and driven by a servo driver. According to the load conditions of the five control objects, four 5KW servo motors and one 7KW servo motor are used for driving. The servo motor is equipped with a brake and an absolute position encoder. The brake is used to prevent the mechanism from moving due to external forces when it is stationary. The encoder is used to feedback the speed and position information of the mechanism to achieve precise control. The lower computer of the system can be controlled by the touch screen on the control cabinet, or by the upper computer in the control room. The upper computer can implement static operation and dynamic adjustment on the control object.
由于下位机是根据上位机的测控参数进行测控试验过程的控制，如果上位机与下位机间的通信产生延时，则会造成对测控控制的滞后，导致测控数据的不准确，影响测控精度。为保障上位机与下位机间通信的实时性及稳定性。上位机与下位机之间，通过TCP协议传输关键数据，例如目标马赫数、当前马赫数、总压、静压、开机、关机等控制数据，TCP通信周期设置为50ms；关键数据以外的其他数据，则使用OPC协议进行数据交互，OPC通信周期设置为100ms。Since the lower computer controls the measurement and control test process according to the measurement and control parameters of the upper computer, if there is a delay in the communication between the upper computer and the lower computer, it will cause a lag in the measurement and control, resulting in inaccurate measurement and control data and affecting the measurement and control accuracy. In order to ensure the real-time and stability of communication between the upper computer and the lower computer. Between the upper computer and the lower computer, the TCP protocol is used to transmit key data, such as the target Mach number, current Mach number, total pressure, static pressure, power on, power off and other control data. The TCP communication cycle is set to 50ms; for other data other than key data, the OPC protocol is used for data exchange, and the OPC communication cycle is set to 100ms.
另外，PLC运动控制系统和PXI测量系统之间，由于PLC运动控制系统需要PXI测量系统反馈的数据进行闭环控制，因此，同样需要确保两者通信间的及时性，否则会造成控制的滞后。为此，PLC运动控制系统与伺服驱动器之间使用PROFINET IRT通信，控制周期设置为4ms，安全连锁信号，以及马赫数与总压控制算法等关键数据放在单独的中断程序块中运行，中断时间可设置为10ms。保障PLC运动控制系统的快速响应。而PXI测量系统中，关键数据及安全连锁信号放在单独的子VI独立运行，通过（while）循环中断调用子VI，循环中断时间可设置10ms，保障数据接收实时响应。此外，对于PXI测量系统与PLC运动控制系统之间的交互的数据，分为了一般信号（如试验终末运行参数）、紧急信号（如紧急停车）和关键数据（如试验中间运行参数），将这些数据按照类别对应的优先级/协议分类发送，其中，紧急信号和关键数据要求响应及时，通信可靠，因此需要配置相应的通信协议进行传输。In addition, since the PLC motion control system needs the data fed back by the PXI measurement system for closed-loop control, it is also necessary to ensure the timeliness of the communication between the two, otherwise it will cause control lag. To this end, PROFINET IRT communication is used between the PLC motion control system and the servo drive, and the control cycle is set to 4ms. The safety interlock signal, as well as key data such as the Mach number and total pressure control algorithm are placed in a separate interrupt program block for operation, and the interrupt time can be set to 10ms. Ensure the rapid response of the PLC motion control system. In the PXI measurement system, key data and safety interlock signals are placed in a separate subVI for independent operation, and the subVI is called through a (while) loop interrupt. The loop interrupt time can be set to 10ms to ensure real-time response of data reception. In addition, the interactive data between the PXI measurement system and the PLC motion control system are divided into general signals (such as test terminal operation parameters), emergency signals (such as emergency stop) and key data (such as test intermediate operation parameters). These data are sent according to the priority/protocol classification corresponding to the category. Among them, emergency signals and key data require timely response and reliable communication, so the corresponding communication protocol needs to be configured for transmission.
在进行试验前，需要先对安装好的系统进行调试，以确保各子系统是正常运转的。调试过程包括对气动设备进气系统、压力调节系统、模型姿态控制系统和辅助系统的调试，统称为系统静调。Before the test, the installed system needs to be debugged to ensure that each subsystem is operating normally. The debugging process includes the debugging of the pneumatic equipment air intake system, pressure regulation system, model attitude control system and auxiliary system, collectively referred to as system static adjustment.
1）进气系统调试1) Intake system debugging
进气系统包括总阀、快速阀以及进气管路等，其中快速阀需要进行控制调试。通过调试，使快速阀开关动作正常，限位准确，并测出阀门单次开、关所需时间。The air intake system includes the main valve, the quick valve and the air intake pipeline, among which the quick valve needs to be controlled and debugged. Through debugging, the quick valve can switch normally, the limit position is accurate, and the time required for the valve to open and close once can be measured.
快速阀是单向作用电动气活门操纵的气动阀门，要求快速开启或关闭，以隔断气源，由控制器输出开关量信号作用于电磁阀进行控制。在气动设备压力或马赫数调节控制中，首先由设定的目标压力或目标马赫数值，根据阀门性能曲线插值计算出主调压阀（或引射调压阀）相应的理论位置值，并控制其预置到位，然后快速阀快速开启，再进入压力或马赫数闭环控制。The quick valve is a pneumatic valve operated by a one-way electric pneumatic valve. It is required to open or close quickly to cut off the gas source. The controller outputs a switch signal to act on the solenoid valve for control. In the pressure or Mach number regulation and control of pneumatic equipment, the corresponding theoretical position value of the main pressure regulating valve (or injection pressure regulating valve) is first calculated by interpolation of the valve performance curve based on the set target pressure or target Mach value, and controlled to preset it in place, and then the quick valve is opened quickly, and then the pressure or Mach number closed-loop control is entered.
快速阀控制利用PLC主控制器输出开关信号，控制中间继电器，控制电磁阀通断以驱动阀门作开、关操作。The fast valve control uses the PLC main controller to output the switch signal, control the intermediate relay, and control the on and off of the solenoid valve to drive the valve to open and close.
快速阀控制调试方法包括：The fast valve control debugging method includes:
a.硬件线路确认，a. Hardware circuit confirmation,
控制系统硬件回路的所有电气连接已经完成并经检查与通电测试，确认无误；All electrical connections of the control system hardware circuit have been completed and checked and tested for correctness;
b.开、关动作调试，b. Open and close action debugging,
接通电磁阀，分别启动阀门作开、关运动，观察阀门是否启停正常、运行平稳、无别卡，限位开关是否能正常起到运行保护；Connect the solenoid valve, start the valve to open and close respectively, observe whether the valve starts and stops normally, runs smoothly, and has no jams, and whether the limit switch can function normally as an operating protection;
c.开/关时间测定，c. On/off time determination,
启动阀门开、关运行，并利用秒表计时，记录快速阀阀单次开/关所需时间。Start the valve opening and closing operation, and use a stopwatch to record the time required for a single opening/closing of the fast valve.
2）压力调节系统调试，2) Debugging of pressure regulation system,
气动设备的压力调节系统包括主调压阀、引射调压阀控制系统、增引阀控制系统等，其中主调压阀、引射调压阀、增引阀需要进行控制调试。通过调试，确认主调节阀、引射调压阀、增引阀运行正常，限位准确，并测出主调节阀、引射调压阀、增引阀运行的总行程、定位精度、运行速度。The pressure regulation system of pneumatic equipment includes the main pressure regulating valve, the ejection pressure regulating valve control system, the boost valve control system, etc. Among them, the main pressure regulating valve, the ejection pressure regulating valve, and the boost valve need to be controlled and debugged. Through debugging, it is confirmed that the main regulating valve, the ejection pressure regulating valve, and the boost valve are operating normally and the limit is accurate, and the total stroke, positioning accuracy, and operating speed of the main regulating valve, the ejection pressure regulating valve, and the boost valve are measured.
本实施例主调压阀选用西门子1FL6系列伺服电机，型号为：1FL6094-1AC61-2LH1，具体参数如下：电机额定功率：5.0kW，电机额定转速：2000r/min，最大转速：2500r/min。电机额定扭矩：23.9Nm，带抱闸。减速比为90：1，输出转速：27.78r/min，输出扭矩：663.9Nm。驱动器配置电源滤波器，用以隔离对电源的污染，抑制供电回路的的干扰。电机自带旋转绝对值编码器反馈，闭环控制。驱动器选用西门子与1FL6系列电机配套的V90系列伺服驱动器，主调压阀电机伺服驱动器选用型号为：6SL3210-5FE15-0UF0。驱动器与PLC运行控制系统采PROFINET IRT实时通信进行数据交互，运动控制器算法由PLC运动控制器完成。PLC型号：CPU1515T-2PN。In this embodiment, the main pressure regulating valve uses Siemens 1FL6 series servo motor, model: 1FL6094-1AC61-2LH1, and the specific parameters are as follows: motor rated power: 5.0kW, motor rated speed: 2000r/min, maximum speed: 2500r/min. Motor rated torque: 23.9Nm, with brake. The reduction ratio is 90:1, the output speed: 27.78r/min, and the output torque: 663.9Nm. The driver is equipped with a power filter to isolate the pollution of the power supply and suppress the interference of the power supply circuit. The motor has its own rotary absolute encoder feedback and closed-loop control. The driver uses Siemens V90 series servo driver that is compatible with the 1FL6 series motor, and the main pressure regulating valve motor servo driver uses the model: 6SL3210-5FE15-0UF0. The driver and the PLC operation control system use PROFINET IRT real-time communication for data exchange, and the motion controller algorithm is completed by the PLC motion controller. PLC model: CPU1515T-2PN.
主调节阀控制调试方法包括：The main regulating valve control debugging method includes:
a.硬件线路确认，a. Hardware circuit confirmation,
主调节阀系统电机动力线、电机编码器线、外接编码器线、限位开关线连接已经完成并经检查与测试，确认无误；The main control valve system motor power line, motor encoder line, external encoder line, and limit switch line have been connected and checked and tested to confirm that they are correct;
b.运行调试，b. Run the debugger,
初次通电调试：将阀门手动摇至阀门中间位置，将此位置设为调试的零位，主调节阀驱动器上电、使能、输入位置5mm、输入速度0.5mm/s，运行；观察阀门运行电流情况是否正常，现场人员注意听是否有异响。一旦发生异常情况立即急停，调试直至正常运行。上电运行正常，无故障。Initial power-on debugging: Manually swing the valve to the middle position of the valve, set this position as the zero position for debugging, power on the main control valve driver, enable, input position 5mm, input speed 0.5mm/s, and run; observe whether the valve operating current is normal, and the on-site personnel should listen for any abnormal sound. If an abnormal situation occurs, stop immediately and debug until it runs normally. Power on and run normally without any faults.
限位开关调试：在主回路380VAC不通电的情况下，手动触发全开、全关限位开关，观察相应的触点是否接通、模块IO是否输入、控制模块是否停止输出，以起到限位保护作用，然后通过驱动器控制电机运行快接近阀门全关位置停止，然后由手摇至阀门完全密封的位置。限位器拨到全关位置确认限位开关已经撞上后装在减速箱相应的位置，通过手摇反复碰撞限位开关，用万用表检测限位开关是否限位接通。观察阀体实际位置是否已经达到极限位置，若实际阀门位置还没有到达极限位置，需拆下限位开关后通过手摇至极限位置，再装上限位开关，最后通过驱动器控制电机撞限位停止，观察阀体是否到达极限位置，开限位以相同的方式调试。如此调试直至完成。Limit switch debugging: When the main circuit 380VAC is not powered, manually trigger the fully open and fully closed limit switches, observe whether the corresponding contacts are connected, whether the module IO is input, and whether the control module stops output, so as to play a limit protection role, and then control the motor to stop when the valve is close to the fully closed position through the driver, and then manually crank the valve to the position where it is completely sealed. After the limiter is dialed to the fully closed position to confirm that the limit switch has hit, install it in the corresponding position of the reduction box, repeatedly hit the limit switch by hand, and use a multimeter to detect whether the limit switch is connected. Observe whether the actual position of the valve body has reached the limit position. If the actual valve position has not reached the limit position, remove the limit switch and manually crank it to the limit position, then install the upper limit switch, and finally control the motor to hit the limit stop through the driver, observe whether the valve body has reached the limit position, and debug the open limit in the same way. Debug in this way until completed.
定位精度：阀门回到全关位置，标记零位，阀门分零位、10mm、20mm、30mm、40mm、50mm、100mm、150mm、210mm位置运行，测量实际位置达到控制精度要求；检测回程间隙，首先往一个方向运行一段位置停止再按照0.1mm一个阶梯递加反向运行，直到阀门位置刚刚移动停止，记录给定位置；如此重复测量多次，直至达到精度要求。Positioning accuracy: The valve returns to the fully closed position and the zero position is marked. The valve is operated at the zero position, 10mm, 20mm, 30mm, 40mm, 50mm, 100mm, 150mm and 210mm positions, and the actual position is measured to meet the control accuracy requirements. To detect the return clearance, first run in one direction for a position and stop, then run in the opposite direction in steps of 0.1mm until the valve position just moves and stops, and record the given position. Repeat the measurement multiple times until the accuracy requirements are met.
总行程的确认：以阀门全关限位为零位走到全开限位，记录运行位置，现场人员测量并记录数据。Confirmation of total stroke: Take the fully closed limit of the valve as zero position and move to the fully open limit position, record the operating position, and the on-site personnel measure and record the data.
运行速度调试：分别以1mm/s、2mm/s、3mm/s、3.5mm/s运行，现场人员注意是否有异常声音，调试人员监控电机运行电流及速度曲线，观察机构的动态响应特性，修改相应的参数，直到各速度运行正常。Running speed debugging: run at 1mm/s, 2mm/s, 3mm/s, and 3.5mm/s respectively. On-site personnel pay attention to whether there is any abnormal sound. The debugging personnel monitor the motor running current and speed curve, observe the dynamic response characteristics of the mechanism, and modify the corresponding parameters until each speed runs normally.
本实施例引射阀选用西门子1FL6系列伺服电机，型号为：1FL6094-1AC61-2LH1，具体参数如下：电机额定功率：5.0kW，电机额定转速：2000r/min，最大转速：2500r/min。电机额定扭矩：23.9Nm，带抱闸。减速比为22.5：1，输出转速：111.11r/min，输出扭矩：537.75Nm。驱动器配置电源滤波器，用以隔离对电源的污染，抑制供电回路的干扰。电机自带旋转绝对值编码器反馈，实现闭环控制。驱动器选用西门子与1FL6系列电机配套的V90系列伺服驱动器，引射调压阀电机伺服驱动器选用型号为：6SL3210-5FE15-0UF0。驱动器与PLC控制系统采PROFINET IRT实时通信进行数据交互，运动控制器算法由PLC运动控制器完成。The ejection valve of this embodiment uses Siemens 1FL6 series servo motor, model: 1FL6094-1AC61-2LH1, and the specific parameters are as follows: motor rated power: 5.0kW, motor rated speed: 2000r/min, maximum speed: 2500r/min. Motor rated torque: 23.9Nm, with brake. The reduction ratio is 22.5:1, output speed: 111.11r/min, output torque: 537.75Nm. The driver is equipped with a power filter to isolate the pollution of the power supply and suppress the interference of the power supply circuit. The motor comes with a rotary absolute encoder feedback to achieve closed-loop control. The driver uses Siemens V90 series servo driver that is compatible with the 1FL6 series motor, and the ejection pressure regulating valve motor servo driver uses the model: 6SL3210-5FE15-0UF0. The driver and the PLC control system use PROFINET IRT real-time communication for data exchange, and the motion controller algorithm is completed by the PLC motion controller.
引射阀控制调试方法包括：The control debugging method of the ejector valve includes:
a.硬件线路确认，a. Hardware circuit confirmation,
引射调节阀系统电机动力线、电机编码器线、外接编码器线、限位开关线连接已经完成并经检查与测试，确认无误；The connection of the motor power line, motor encoder line, external encoder line and limit switch line of the ejector control valve system has been completed and checked and tested to be correct;
b.运行调试，b. Run the debugger,
初次通电调试：将阀门手动摇至阀门中间位置，将此位置设为调试的零位，引射调节阀驱动器上电、使能、输入位置5mm、输入速度0.5mm/s，点击运行按钮；观察阀门运行电流情况是否正常，现场人员注意听是否有异响。一旦发生异常情况立即急停，调试直至正常运行。运行时，伺服使能，电机报错，错误代码:F31111，伺服电机编码器故障，经检查，发现伺服电机编码器接头处有异物，清除后，重新上电，故障排除。Initial power-on debugging: Manually shake the valve to the middle position of the valve, set this position as the zero position for debugging, power on the ejector control valve driver, enable it, input the position 5mm, input the speed 0.5mm/s, and click the run button; observe whether the valve operating current is normal, and the on-site personnel should listen for any abnormal sounds. Once an abnormal situation occurs, stop immediately and debug until it runs normally. During operation, the servo is enabled, the motor reports an error, and the error code is: F31111. The servo motor encoder is faulty. After inspection, it is found that there is foreign matter in the servo motor encoder connector. After clearing it, power it on again and the fault is eliminated.
限位开关调试：在主回路380VAC不通电的情况下，手动触发全开、全关限位开关，观察相应的触点是否接通、模块IO是否输入、控制模块是否停止输出，以起到限位保护作用，然后通过驱动器控制电机运行快接近阀门全关位置停止，然后由手摇至阀门完全密封的位置。限位器拨到全关位置确认限位开关已经撞上后装在减速箱相应的位置，通过手摇反复碰撞限位开关，用万用表检测限位开关是否限位接通。观察阀体实际位置是否已经达到极限位置，若实际阀门位置还没有到达极限位置，需拆下限位开关后通过手摇至极限位置，再装上限位开关，最后通过驱动器控制电机撞限位停止，观察阀体是否到达极限位置，开限位以相同的方式调试。如此调试直至完成。Limit switch debugging: When the main circuit 380VAC is not powered, manually trigger the fully open and fully closed limit switches, observe whether the corresponding contacts are connected, whether the module IO is input, and whether the control module stops output, so as to play a limit protection role, and then control the motor to stop when the valve is close to the fully closed position through the driver, and then manually crank the valve to the position where it is completely sealed. After the limiter is dialed to the fully closed position to confirm that the limit switch has hit, install it in the corresponding position of the reduction box, repeatedly hit the limit switch by hand, and use a multimeter to detect whether the limit switch is connected. Observe whether the actual position of the valve body has reached the limit position. If the actual valve position has not reached the limit position, remove the limit switch and manually crank it to the limit position, then install the upper limit switch, and finally control the motor to hit the limit stop through the driver, observe whether the valve body has reached the limit position, and debug the open limit in the same way. Debug in this way until completed.
定位精度：阀门回到全关位置，测量人员做好零位标记，阀门分零位、50mm、100mm、150mm、200mm、250mm、270mm位置运行，测量实际位置达到控制精度要求；检测回程间隙，首先往一个方向运行一段位置停止再按照0.1mm一个阶梯递加反向运行，直到阀门位置刚刚移动停止，记录给定位置；如此重复测量多次，直至达到精度要求。Positioning accuracy: When the valve returns to the fully closed position, the measurement personnel mark the zero position. The valve is operated at zero position, 50mm, 100mm, 150mm, 200mm, 250mm and 270mm positions, and the actual position is measured to meet the control accuracy requirements. To detect the return clearance, first run in one direction for a position and stop, then run in the opposite direction in steps of 0.1mm until the valve position just moves and stops, and record the given position. Repeat the measurement multiple times until the accuracy requirements are met.
总行程的确认：以阀门全关限位为零位走到全开限位，记录运行位置，现场人员测量并记录数据。Confirmation of total stroke: Take the fully closed limit of the valve as zero position and move to the fully open limit position, record the operating position, and the on-site personnel measure and record the data.
运行速度调试：分别以1mm/s、2mm/s、3mm/s、4mm/s、5mm/s、6mm/s、7mm/s、8mm/s、9mm/s、10mm/s运行，现场人员注意是否有异常声音，调试人员监控电机运行电流及速度曲线，观察机构的动态响应特性，修改相应的参数，直到各速度运行正常。Running speed debugging: run at 1mm/s, 2mm/s, 3mm/s, 4mm/s, 5mm/s, 6mm/s, 7mm/s, 8mm/s, 9mm/s and 10mm/s respectively. On-site personnel pay attention to whether there is any abnormal sound. The debugging personnel monitor the motor running current and speed curve, observe the dynamic response characteristics of the mechanism, and modify the corresponding parameters until each speed runs normally.
本实施例增引阀选用西门子1FL6系列伺服电机，型号为：1FL6096-1AC61-2LH1，具体参数如下：电机额定功率：7.0kW，电机额定转速：2000r/min，最大转速：2500r/min。电机额定扭矩：40Nm，带抱闸。减速比为560：1，输出转速：4.46r/min，输出扭矩：22400Nm。驱动器配置电源滤波器，用以隔离对电源的污染，抑制供电回路的的干扰。电机自带旋转绝对值编码器反馈，实现闭环控制。驱动器选用西门子与1FL6系列电机配套的V90系列伺服驱动器，引射调压阀电机伺服驱动器选用型号为：6SL3210-5FE17-0UF0。驱动器与PLC控制系统采PROFINET IRT实时通信进行数据交互，运动控制器算法由PLC运动控制器完成。In this embodiment, the boost valve uses Siemens 1FL6 series servo motor, model: 1FL6096-1AC61-2LH1, and the specific parameters are as follows: motor rated power: 7.0kW, motor rated speed: 2000r/min, maximum speed: 2500r/min. Motor rated torque: 40Nm, with brake. The reduction ratio is 560:1, the output speed: 4.46r/min, and the output torque: 22400Nm. The driver is equipped with a power filter to isolate the pollution of the power supply and suppress the interference of the power supply circuit. The motor comes with a rotary absolute encoder feedback to achieve closed-loop control. The driver uses Siemens V90 series servo driver that is compatible with the 1FL6 series motor, and the servo driver of the boost pressure regulating valve motor uses the model: 6SL3210-5FE17-0UF0. The driver and the PLC control system use PROFINET IRT real-time communication for data exchange, and the motion controller algorithm is completed by the PLC motion controller.
增引阀控制调试方法包括：The control debugging methods of the boost valve include:
a.硬件线路确认，a. Hardware circuit confirmation,
增引阀系统电机动力线、电机编码器线、外接编码器线、限位开关线连接已经完成并经检查与测试，确认无误；The connection of the motor power line, motor encoder line, external encoder line and limit switch line of the boost valve system has been completed and checked and tested to be correct;
2)运行调试，2) Run the debugger,
初次通电调试：将阀门手动控制至阀门中间位置，将此位置设为调试的零位，引射调节阀驱动器上电、使能、输入位置5mm、输入速度0.5mm/s，点击运行按钮；观察阀门运行电流情况是否正常，现场人员注意听是否有异响。一旦发生异常情况立即急停，调试直至正常运行。运行时，发现电机启动以及停止时，发出较大撞击声响，经分析为电机加减速设置太快，电机骤起骤停，对减速箱齿轮造成冲击，通过优化加减速设置，使电机启动、停止平缓后，无异响，运行稳定。Initial power-on debugging: Manually control the valve to the middle position of the valve, set this position as the zero position for debugging, power on the ejector control valve driver, enable, input position 5mm, input speed 0.5mm/s, and click the run button; observe whether the valve operating current is normal, and the on-site personnel should listen for any abnormal sounds. Once an abnormal situation occurs, stop immediately and debug until it runs normally. During operation, it was found that when the motor started and stopped, a loud impact sound was made. After analysis, it was found that the motor acceleration and deceleration settings were too fast, and the motor started and stopped suddenly, causing an impact on the gearbox gear. By optimizing the acceleration and deceleration settings, the motor started and stopped smoothly, without abnormal sounds, and ran stably.
限位开关调试：在主回路380VAC不通电的情况下，手动触发全开、全关限位开关，观察相应的触点是否接通、模块IO是否输入、控制模块是否停止输出，以起到限位保护作用，然后通过驱动器控制电机运行快接近阀门全关位置停止，然后由手摇至阀门完全密封的位置。限位器拨到全关位置确认限位开关已经撞上后装在减速箱相应的位置，通过手摇反复碰撞限位开关，用万用表检测限位开关是否限位接通。观察阀体实际位置是否已经达到极限位置，若实际阀门位置还没有到达极限位置，需拆下限位开关后通过手摇至极限位置，再装上限位开关，最后通过驱动器控制电机撞限位停止，观察阀体是否到达极限位置，开限位以相同的方式调试。如此调试直至完成。Limit switch debugging: When the main circuit 380VAC is not powered, manually trigger the fully open and fully closed limit switches, observe whether the corresponding contacts are connected, whether the module IO is input, and whether the control module stops output, so as to play a limit protection role, and then control the motor to stop when the valve is close to the fully closed position through the driver, and then manually crank the valve to the position where it is completely sealed. After the limiter is dialed to the fully closed position to confirm that the limit switch has hit, install it in the corresponding position of the reduction box, repeatedly hit the limit switch by hand, and use a multimeter to detect whether the limit switch is connected. Observe whether the actual position of the valve body has reached the limit position. If the actual valve position has not reached the limit position, remove the limit switch and manually crank it to the limit position, then install the upper limit switch, and finally control the motor to hit the limit stop through the driver, observe whether the valve body has reached the limit position, and debug the open limit in the same way. Debug in this way until completed.
定位精度：阀门回到全关位置，测量人员做好零位标记，阀门分零位、10mm、20mm、50mm、100mm、150mm、183mm位置运行，测量实际位置达到控制精度要求；检测回程间隙，首先往一个方向运行一段位置停止再按照0.1mm一个阶梯递加反相运行，直到阀门位置刚刚移动停止，记录给定位置；如此重复测量几次，直至达到精度要求。Positioning accuracy: When the valve returns to the fully closed position, the measurement personnel make a zero mark. The valve is operated at zero, 10mm, 20mm, 50mm, 100mm, 150mm, and 183mm positions, and the actual position is measured to meet the control accuracy requirements. To detect the return clearance, first run in one direction for a position and stop, then run in the opposite direction in steps of 0.1mm until the valve position just moves and stops, and record the given position. Repeat the measurement several times until the accuracy requirements are met.
总行程的确认：以阀门全关限位为零位走到全开限位，记录运行位置，现场人员测量并记录数据。Confirmation of total stroke: Take the fully closed limit of the valve as zero position and move to the fully open limit position, record the operating position, and the on-site personnel measure and record the data.
运行速度调试：分别以0.1mm/s、0.2mm/s、0.3mm/s、0.4mm/s、0.5mm/s运行，现场人员注意是否有异常声音，调试人员监控电机运行电流及速度曲线，观察机构的动态响应特性，修改相应的参数，直到各速度运行正常。Running speed debugging: run at 0.1mm/s, 0.2mm/s, 0.3mm/s, 0.4mm/s and 0.5mm/s respectively. On-site personnel pay attention to whether there is any abnormal sound. The debugging personnel monitor the motor running current and speed curve, observe the dynamic response characteristics of the mechanism, and modify the corresponding parameters until each speed runs normally.
3）模型姿态控制系统调试，3) Model attitude control system debugging,
气动设备的模型姿态系统包括老试验段半模、全模与新试验段攻角等，均需要进行控制调试。通过调试，确认全模机构和半模机构运行正常，限位准确，并测出全模机构和半模机构运行的范围、定位精度、运行速度。The model attitude system of the pneumatic equipment includes the old test section half-mold, full-mold and new test section attack angle, etc., all of which need to be controlled and debugged. Through debugging, it is confirmed that the full-mold mechanism and the half-mold mechanism are operating normally and the limit is accurate, and the operating range, positioning accuracy and operating speed of the full-mold mechanism and the half-mold mechanism are measured.
全模机构安装在纵向移动机构上，可随纵向移动机构沿气动设备轴线前后移动。全模机构的运动有两种驱动方式：伺服电机带动蜗轮转动，完成机构的运行；手动调节时，伺服电机松开抱闸，通过手轮、花键副、齿轮组等驱动蜗轮蜗杆，完成机构的运行。在机构正负极限位置均设置行程限位开关。The full-mold mechanism is installed on the longitudinal moving mechanism and can move forward and backward along the axis of the pneumatic equipment with the longitudinal moving mechanism. There are two driving modes for the movement of the full-mold mechanism: the servo motor drives the worm gear to rotate to complete the operation of the mechanism; when manually adjusting, the servo motor releases the brake and drives the worm gear through the handwheel, spline pair, gear set, etc. to complete the operation of the mechanism. Travel limit switches are set at the positive and negative limit positions of the mechanism.
本实施例选用西门子1FL6系列伺服电机，型号为：1FL6094-1AC61-2LH1，具体参数如下：电机额定功率：5.0kW，电机额定转速：2000r/min，最大转速2500r/min；电机额定扭矩：23.9Nm，带抱闸；减速比为300.3:1，输出转速：8.33r/min，输出扭矩：7177.17Nm。驱动器配置电源滤波器，用以隔离对电源的污染，抑制供电回路的的干扰。电机自带旋转绝对值编码器反馈，实现闭环控制。驱动器选用西门子与1FL6系列电机配套的V90系列伺服驱动器，全模机构电机伺服驱动器选用型号为：6SL3210-5FE15-0UF0。驱动器与PLC控制系统采PROFINET IRT实时通信进行数据交互，运动控制器算法由PLC运动控制器完成。This embodiment uses Siemens 1FL6 series servo motors, model: 1FL6094-1AC61-2LH1, and the specific parameters are as follows: motor rated power: 5.0kW, motor rated speed: 2000r/min, maximum speed 2500r/min; motor rated torque: 23.9Nm, with brake; reduction ratio is 300.3:1, output speed: 8.33r/min, output torque: 7177.17Nm. The driver is equipped with a power filter to isolate the pollution of the power supply and suppress the interference of the power supply circuit. The motor comes with a rotary absolute encoder feedback to achieve closed-loop control. The driver uses Siemens V90 series servo drivers that are compatible with 1FL6 series motors, and the full-module mechanism motor servo driver uses the model: 6SL3210-5FE15-0UF0. The driver and the PLC control system use PROFINET IRT real-time communication for data interaction, and the motion controller algorithm is completed by the PLC motion controller.
全模机构位置检测编码器安装于机构尾部，随蜗轮旋转，蜗轮旋转一圈，编码器旋转一圈，对应全模机构运行2°。全模机构运动范围±15°，共计30°，对应编码器旋转1圈。编码器选择多圈绝对式编码器。选用上海精浦机电GMX60多圈绝对型旋转编码器，GMX60R12/12E10SGB，该编码器分辨率1/4096，连续4096圈，采用RS422数据通讯接口，SSI通讯协议，工作电压4.5～32V，格雷码输出，工作温度-20～100℃。The position detection encoder of the full-mode mechanism is installed at the tail of the mechanism and rotates with the worm wheel. The encoder rotates one circle when the worm wheel rotates one circle, corresponding to 2° operation of the full-mode mechanism. The motion range of the full-mode mechanism is ±15°, a total of 30°, corresponding to 1 circle of encoder rotation. The encoder is a multi-turn absolute encoder. Shanghai Jingpu Electromechanical GMX60 multi-turn absolute rotary encoder, GMX60R12/12E10SGB, is selected. The encoder has a resolution of 1/4096, 4096 continuous circles, uses RS422 data communication interface, SSI communication protocol, working voltage 4.5~32V, Gray code output, working temperature -20~100℃.
全模机构系统调试方法包括：The full-model mechanism system debugging method includes:
a.硬件线路确认，a. Hardware circuit confirmation,
全模机构系统电机动力线、电机编码器线、限位开关线连接已经完成并经检查与测试，确认无误。The connections of the motor power line, motor encoder line, and limit switch line of the full-module mechanism system have been completed and checked and tested to be correct.
b.运行调试，b. Run the debugger,
初次通电调试：将全模机构手动摇至水平位置，将此位置设为调试的零位，驱动器上电、使能、输入角度1°、输入速度0.1°/s，点击运行按钮；观察运行电流及速度情况是否正常，现场人员注意听是否有异响，一旦发生异常情况立即急停；调试过程中电流偏大，转动声音较大，经结构人员检查分析，涡轮涡杆中有灰尘，增大了运行载荷，通过安装人员的清洗并打上机油后运行，电流恢复正常。调试直至正常运行。Initial power-on debugging: Manually shake the full-mode mechanism to a horizontal position, set this position as the zero position for debugging, power on the driver, enable it, input an angle of 1°, input a speed of 0.1°/s, and click the run button; observe whether the operating current and speed are normal, and the on-site personnel should listen carefully for any abnormal sounds, and immediately stop the machine in case of any abnormality; during the debugging process, the current was too high and the rotation sound was loud. After inspection and analysis by the structural personnel, it was found that there was dust in the turbine worm shaft, which increased the operating load. After the installer cleaned it and applied oil, the current returned to normal. Debug until normal operation.
限位开关调试：在主回路380VAC不通电的情况下，手动触发正、负限位开关，观察相应的触点是否接通、模块IO是否输入、控制模块是否停止输出，以起到限位保护作用，然后通过驱动器驱动伺服电机运行到快接近限位开关的位置停止，由手摇至限位位置开关触发，观察机构实际位置是否已经达到极限位置，若实际机构位置还没有到达极限位置，需拆下限位开关后通过手摇机构至极限位置，再装上限位开关，最后通过驱动器控制电机撞限位停止，实际位置到达极限位置，调试直至完成。Limit switch debugging: When the main circuit 380VAC is not powered, manually trigger the positive and negative limit switches to observe whether the corresponding contacts are connected, whether the module IO is input, and whether the control module stops outputting to play a limit protection role. Then drive the servo motor through the driver to run to a position close to the limit switch and stop. Trigger the limit position switch by hand and observe whether the actual position of the mechanism has reached the limit position. If the actual mechanism position has not reached the limit position, remove the limit switch and hand-crank the mechanism to the limit position, then install the upper limit switch, and finally control the motor to hit the limit stop through the driver. The actual position reaches the limit position and the debugging is completed.
定位精度：全模机构回到零位，测量人员做好零位标记，机构分-10°、-5°零位、5°、10°、15°角度运行，测量实际角度，直至达到精度要求。经调试测量，机构反向间隙0.07°，通过软件算法，增加方向间隙补偿，消除间隙后满足精度要求。Positioning accuracy: The full-mold mechanism returns to zero position, and the measurement personnel mark the zero position. The mechanism runs at -10°, -5° zero position, 5°, 10°, and 15° angles, and the actual angle is measured until the accuracy requirement is met. After debugging and measurement, the reverse clearance of the mechanism is 0.07°. Through the software algorithm, the directional clearance compensation is increased, and the accuracy requirement is met after the clearance is eliminated.
总行程的确认：以机构水平位置为零位走到负限位，由负限位开始走到正限位，记录运行位置，现场人员测量并记录数据。Confirmation of total stroke: take the horizontal position of the mechanism as zero and move to the negative limit, then move from the negative limit to the positive limit, record the running position, and the on-site personnel measure and record the data.
运行速度调试：分别以0.1°/s、0.2°/s、0.5°/s、1.0°/s、1.1°/s运行，现场人员注意是否有异常声音，调试人员监控电机运行电流及速度曲线，观察机构的动态响应特性，修改相应的参数，直到各速度运行正常。Running speed debugging: run at 0.1°/s, 0.2°/s, 0.5°/s, 1.0°/s, and 1.1°/s respectively. On-site personnel pay attention to whether there are abnormal sounds. The debugging personnel monitor the motor running current and speed curve, observe the dynamic response characteristics of the mechanism, and modify the corresponding parameters until each speed runs normally.
半模机构用于翼型试验、半模试验和其他需要侧壁支撑的特种试验。半模机构的运动有两种驱动方式：伺服电机带动蜗轮转动，完成机构的运行；手动调节时，伺服电机松开抱闸，通过手轮、花键副、齿轮组等驱动蜗轮蜗杆，完成机构的运行。The half-mold mechanism is used for airfoil tests, half-mold tests and other special tests that require side wall support. There are two driving modes for the movement of the half-mold mechanism: the servo motor drives the worm gear to rotate to complete the operation of the mechanism; when manually adjusting, the servo motor releases the brake and drives the worm gear through the handwheel, spline pair, gear set, etc. to complete the operation of the mechanism.
本实施例选用西门子1FL6系列伺服电机，型号为：1FL6094-1AC61-2LH1，具体参数如下：电机额定功率：5.0kW，电机额定转速：2000r/min，最大转速2500r/min。电机额定扭矩：23.9Nm，带抱闸。减速比为300：1，输出转速：8.33r/min，输出扭矩：7170Nm。驱动器配置电源滤波器，用以隔离对电源的污染，抑制供电回路的的干扰。电机自带旋转绝对值编码器反馈，实现闭环控制。驱动器选用西门子与1FL6系列电机配套的V90系列伺服驱动器，半模机构电机伺服驱动器选用型号为：6SL3210-5FE15-0UF0。驱动器与PLC控制系统采PROFINETIRT实时通信进行数据交互，运动控制器算法由PLC运动控制器完成。This embodiment uses Siemens 1FL6 series servo motors, model: 1FL6094-1AC61-2LH1, and the specific parameters are as follows: motor rated power: 5.0kW, motor rated speed: 2000r/min, maximum speed 2500r/min. Motor rated torque: 23.9Nm, with brake. The reduction ratio is 300:1, the output speed: 8.33r/min, and the output torque: 7170Nm. The driver is equipped with a power filter to isolate the pollution of the power supply and suppress the interference of the power supply circuit. The motor comes with a rotary absolute encoder feedback to achieve closed-loop control. The driver uses Siemens V90 series servo drivers that are compatible with 1FL6 series motors, and the semi-module motor servo driver uses the model: 6SL3210-5FE15-0UF0. The driver and the PLC control system use PROFINETIRT real-time communication for data interaction, and the motion controller algorithm is completed by the PLC motion controller.
半模机构位置检测使用倾角传感器，随模型安装，模型转动1°，传感器转动1°，半模机构运动范围±180°，共计360°，对应倾角传感器转动360°。倾角传感器选择瑞芬HCA716倾角传感器，测量范围±180°，分辨率0.005°，温度范围-40-85℃。The half-mold mechanism position detection uses an inclination sensor, which is installed with the model. The model rotates 1°, the sensor rotates 1°, the half-mold mechanism movement range is ±180°, a total of 360°, and the corresponding inclination sensor rotates 360°. The inclination sensor selects Ruifen HCA716 inclination sensor, with a measurement range of ±180°, a resolution of 0.005°, and a temperature range of -40-85℃.
半模机构系统调试方法包括：The debugging method of the half-mold mechanism system includes:
a.硬件线路确认，a. Hardware circuit confirmation,
半模机构系统电机动力线、电机编码器线、已经完成并经检查与测试，确认无误。The motor power line and motor encoder line of the semi-mold mechanism system have been completed and inspected and tested to be correct.
b.运行调试，b. Run the debugger,
初次通电调试：将半模机构手动摇至垂直位置，将此位置设为调试的零位，驱动器上电、使能、输入角度1°、输入速度0.1°/s，点击运行按钮；观察运行电流及速度情况是否正常，现场人员注意听是否有异响，一旦发生异常情况立即急停。电机初次上电无故障，运行正常。Initial power-on debugging: Manually shake the half-mold mechanism to the vertical position, set this position as the zero position for debugging, power on the driver, enable, input angle 1°, input speed 0.1°/s, click the run button; observe whether the operating current and speed are normal, and the on-site personnel should listen for any abnormal sounds, and immediately stop the machine in case of any abnormal situation. The motor is fault-free and operates normally when it is powered on for the first time.
限位开关调试：本半模机构无限位开关Limit switch debugging: This half-mold mechanism has no limit switch
定位精度：半模机构回到零位，测量人员做好零位标记，机构分-180°、-150°、-100°、-50°零位、50°、100°、150°、180°运行，测量实际角度，直至达到精度要求。Positioning accuracy: The half-mold mechanism returns to the zero position, the measurement personnel make a zero mark, the mechanism runs at -180°, -150°, -100°, -50° zero position, 50°, 100°, 150°, 180°, and the actual angle is measured until the accuracy requirement is met.
总行程的确认：以机构垂直位置为零位走到-180°，由-180开始走到+180°，记录运行位置，现场人员测量并记录数据。Confirmation of total stroke: take the vertical position of the mechanism as zero and move to -180°, then move from -180° to +180°, record the running position, and the on-site personnel measure and record the data.
运行速度调试：分别以1°/s、5°/s、10°/s、25°/s、40°/s运行，现场人员注意是否有异常声音，调试人员监控电机运行电流及速度曲线，观察机构的动态响应特性，修改相应的参数，直到各速度运行正常。Running speed debugging: run at 1°/s, 5°/s, 10°/s, 25°/s, and 40°/s respectively. On-site personnel pay attention to whether there are abnormal sounds. The debugging personnel monitor the motor running current and speed curve, observe the dynamic response characteristics of the mechanism, and modify the corresponding parameters until each speed runs normally.
4）辅助系统控制系统调试，4) Auxiliary system control system debugging,
气动设备的辅助系统包括纵向移动机构、驻室大门、充气密封等，充气密封需要进行控制调试。通过调试，实现密封圈自动充气和自动泄压；在现场气控柜上由压力表显示气路的工作压力。The auxiliary systems of pneumatic equipment include longitudinal moving mechanism, room door, inflatable seal, etc. The inflatable seal needs to be controlled and debugged. Through debugging, the sealing ring can be automatically inflated and automatically depressurized; the working pressure of the gas circuit is displayed by the pressure gauge on the on-site gas control cabinet.
密封围带所处的位置：驻室左/右大门密封围带、喷管段与收缩段间密封围带、试验段与喷管段法兰间密封围带、喷管块上密封围带、喷管块下密封围带。共6处密封围带。充气密封围带加压操作在气动设备吹风前的准备阶段完成，控制系统对充气密封压力进行监测并将其纳入安全连锁操作流程。The location of the sealing belt: the sealing belt of the left/right door of the station room, the sealing belt between the nozzle section and the contraction section, the sealing belt between the test section and the nozzle section flange, the sealing belt on the nozzle block, and the sealing belt under the nozzle block. There are 6 sealing belts in total. The pressurization operation of the inflatable sealing belt is completed in the preparation stage before the pneumatic equipment is blown. The control system monitors the inflatable sealing pressure and incorporates it into the safety interlocking operation process.
充气密封气控系统调试方法包括：The debugging method of the inflatable seal air control system includes:
a.硬件线路及气路管路确认，a. Confirmation of hardware circuits and gas pipelines,
充气密封各压力传感器线、电磁阀线、气路管路连接完成并检查与测试，确认无误；The pressure sensor lines, solenoid valve lines, and gas pipelines are connected and inspected and tested to ensure they are correct.
b.通气调试，b. Ventilation debugging,
首先分别给各电磁阀通电/断电，现场人员仔细听是否有动作声音；然后打开气源手动阀门，打开充气电磁阀，现场人员观察压力表值是否和传感器的值一致，若不一致立即停止充气操作，再次检查线路和程序中压力换算是否正确，直到正常后才能开始充气操作；First, power on/off each solenoid valve, and listen carefully to see if there is any sound of movement; then open the manual valve of the gas source, open the inflation solenoid valve, and observe whether the pressure gauge value is consistent with the sensor value. If not, stop the inflation operation immediately, and check again whether the pressure conversion in the circuit and program is correct. The inflation operation can be started only after it is normal;
c.运行调试，c. Run the debugger,
充气（点击充气按钮），观察压力值是否到达目标值，是否停止充气，停止充气后将压力慢慢降低，当达到误差限值时，观察是否自动补气，直到完成该功能；超压功能测试，将目标压力值改小，观察是否自动放气，直到完成。Inflate (click the inflation button), observe whether the pressure value reaches the target value, whether to stop inflation, and slowly reduce the pressure after stopping inflation. When the error limit is reached, observe whether it is automatically replenished until the function is completed; overpressure function test, reduce the target pressure value, and observe whether it is automatically deflated until it is completed.
5）安全联锁系统调试，5) Safety interlock system debugging,
在整个的气动设备控制系统中，设置两级安全联锁系统，一方面主控制系统的主控制器专门开设一个最高优先级的扫描任务，对系统关键参数及关键状态进行检测，并设计相应的安全联锁算法，作为系统的第一级安全联锁保护；另一方面利用现场硬件接线进行安全联锁，以避免通讯传输故障等特殊情况下控制系统失控等紧急状况，此作为控制系统的第二级安全联锁保护。两级安全联锁系统为并行工作方式，任何一级系统检测到故障信息，均进入故障处理程序。In the entire pneumatic equipment control system, a two-level safety interlock system is set up. On the one hand, the main controller of the main control system specially opens a scanning task with the highest priority to detect the key parameters and key states of the system, and designs the corresponding safety interlock algorithm as the first-level safety interlock protection of the system; on the other hand, the safety interlock is performed by using the on-site hardware wiring to avoid emergency situations such as loss of control of the control system under special circumstances such as communication transmission failure, which serves as the second-level safety interlock protection of the control system. The two-level safety interlock system works in parallel. When any level system detects fault information, it enters the fault handling procedure.
启动气动设备必须具备以下条件；洞内无工作人员；混合室人孔必须关闭；驻室大门已关闭；充气密封正常；操纵台电钥匙打开（开车允许）；系统网络通讯已正确建立。The following conditions must be met to start pneumatic equipment: there are no workers in the cave; the manhole of the mixing chamber must be closed; the door of the room is closed; the inflation seal is normal; the electric key on the control panel is turned on (driving is allowed); and the system network communication has been correctly established.
气动设备运行过程必须监测量包括：总压是否超压（绝压不高于1.5个大气压，可设置）；网络是否意外中断；The quantities that must be monitored during the operation of pneumatic equipment include: whether the total pressure is overpressure (the absolute pressure is not higher than 1.5 atmospheres, which can be set); whether the network is accidentally interrupted;
气动设备附近巡视工作人员一旦发现异常，可以通过控制台或控制柜“急停”按钮发送关机请求，安全联锁控制系统检测到该信号则采取相应措施。Once the patrol staff near the pneumatic equipment finds any abnormality, they can send a shutdown request through the "emergency stop" button on the console or control cabinet. The safety interlock control system will detect the signal and take corresponding measures.
由此可知，安全联锁控制系统是作为气动设备开车及应急处置的保护系统，需要确保其运行的准确性。通过调试，实现在试验之前，检测开车允许信号，当保证气动设备安全运行的所有条件均满足，才可解除锁定，允许开车。在试验过程中，该系统一旦检测到危险报警信号，立即按照预定的方式进入故障处理程序，以确保安全。It can be seen that the safety interlock control system is a protection system for the start-up and emergency response of pneumatic equipment, and its operation accuracy must be ensured. Through debugging, the start-up permission signal is detected before the test. When all conditions for the safe operation of the pneumatic equipment are met, the lock can be released and the start-up can be allowed. During the test, once the system detects a dangerous alarm signal, it immediately enters the fault handling procedure in a predetermined manner to ensure safety.
安全联锁控制系统调试方法包括：The debugging methods of safety interlock control system include:
首先做好开车准备，开车允许灯点亮，然后分别以：洞内有人；混合室人孔未关闭；驻室大门未关闭；充气密封异常；操纵台电钥匙未打开（开车允许）；系统网络通讯未正确建立；总压超压（绝压不高于1.5大气压）；网络意外中断；控制柜“急停”为条件，检测开车允许灯是否熄灭，如不能则检查硬件线路是否连接正确，检查程序是否正确执行，直到完全实现气动设备的安全联锁功能。First, make preparations for driving, and turn on the driving permission light. Then, based on the following conditions: there is someone in the tunnel; the manhole of the mixing chamber is not closed; the door of the station room is not closed; the inflation seal is abnormal; the electric key of the control panel is not turned on (driving permission); the system network communication is not correctly established; the total pressure is overpressure (the absolute pressure is not higher than 1.5 atmospheres); the network is accidentally interrupted; the control cabinet is "emergency stop", check whether the driving permission light is off. If not, check whether the hardware circuit is connected correctly and whether the program is executed correctly until the safety interlock function of the pneumatic equipment is fully realized.
6）通气调试，6) Ventilation debugging,
通气调试包括跨声速试验段（对应跨声速模式）和超声速试验段（对应超声速模式）的通气调试。Ventilation debugging includes ventilation debugging of the transonic test section (corresponding to the transonic mode) and the supersonic test section (corresponding to the supersonic mode).
本实例中，跨声速试验段采用0#固定型面喷管，试验马赫数0.3～1.2。通过通气调试，给出在典型马赫数下合适的控制方式与控制参数，以使得控制精度满足要求，同时稳定所需的过渡时间较少。In this example, the transonic test section uses a 0# fixed-profile nozzle, and the test Mach number is 0.3 to 1.2. Through ventilation debugging, the appropriate control method and control parameters are given at the typical Mach number, so that the control accuracy meets the requirements and the transition time required for stability is short.
跨声速试验段是以试验段马赫数为直接受控量，通常马赫数越高总压越高、流量越大，理论上如果阀门流量调节能力足够强，只要气源压力达到目标马赫数总压，通过对主调压阀的开度调节即可实现马赫数调节控制。考虑到主调压阀为伺服电机驱动，相比于液压驱动，其运行速度受限，如果开车时从全关位置的零位开始调节，则需时较长，对气源造成较大浪费。考虑到此，下位机执行的测控试验中，对气动设备马赫数的控制方式为预置阀门开度+阀门开度精调的控制调节方式，即马赫数的控制方法包括两个子步骤，分别为：a.根据设定的“阀门开度-气源压力-马赫数”关系模型（第一关系），配置界面依据当前气源压力与目标马赫数计算推荐匹配的预置阀门开度。b.对阀门开度进行精调。其中，第一预置阀门开度-气源压力关系通过以下方法获得：The transonic test section uses the Mach number of the test section as the directly controlled quantity. Generally, the higher the Mach number, the higher the total pressure and the greater the flow rate. In theory, if the valve flow regulation capability is strong enough, as long as the gas source pressure reaches the target Mach number total pressure, the Mach number regulation control can be achieved by adjusting the opening of the main pressure regulating valve. Considering that the main pressure regulating valve is driven by a servo motor, its operating speed is limited compared to the hydraulic drive. If it is adjusted from the zero position of the fully closed position when driving, it will take a long time and cause a large waste of gas source. Considering this, in the measurement and control test performed by the lower computer, the control method for the Mach number of the pneumatic equipment is the control and adjustment method of the preset valve opening + valve opening fine adjustment, that is, the Mach number control method includes two sub-steps, namely: a. According to the set "valve opening-gas source pressure-Mach number" relationship model (first relationship), the configuration interface calculates the recommended matching preset valve opening based on the current gas source pressure and the target Mach number. b. Fine-tune the valve opening. Among them, the first preset valve opening-gas source pressure relationship is obtained by the following method:
将气源压力保持不变，在安全总压范围内，逐步增加主调压阀开度，实时记录气源压力Pt、调压阀开度比S/Smax、稳定段总压和试验马赫数（即实际马赫数），根据这些记录的数据，由流量公式，结合试验数据获取在不同马赫数Ma下（Ma=0.3、0.4、…、1.2等），主调压阀预置开度与气源压力/目标马赫数的理论关系。如：Keep the gas source pressure constant, within the safe total pressure range, gradually increase the main pressure regulating valve opening, and record the gas source pressure Pt, the pressure regulating valve opening ratio S/Smax, the total pressure in the stable section, and the test Mach number (i.e., the actual Mach number) in real time. Based on these recorded data, the flow formula and the test data are used to obtain the theoretical relationship between the preset opening of the main pressure regulating valve and the gas source pressure/target Mach number at different Mach numbers Ma (Ma=0.3, 0.4, ..., 1.2, etc.). For example:
y=0.101970x4-0.599501x3+1.380635x2-1.722074x+1.174497，（Ma=0.3）；y=0.101970x4 -0.599501x3 +1.380635x2 -1.722074x+1.174497, (Ma=0.3);
y=0.101970x4-0.599501x3+1.380635x2-1.722074x+1.269633,（Ma=0.4）；y=0.101970x4 -0.599501x3 +1.380635x2 -1.722074x+1.269633, (Ma=0.4);
y=0.085888x4-0.518557x3+1.236665x2-1.616401x+1.312122,（Ma=0.5）；y=0.085888x4 -0.518557x3 +1.236665x2 -1.616401x+1.312122, (Ma=0.5);
y=0.073420x4-0.454691x3+1.120428x2-1.528388x+1.340869,（Ma=0.6）；y=0.073420x4 -0.454691x3 +1.120428x2 -1.528388x+1.340869, (Ma=0.6);
y=0.073420x4-0.454691x3+1.120428x2-1.528388x+1.379624,（Ma=0.7）；y=0.073420x4 -0.454691x3 +1.120428x2 -1.528388x+1.379624, (Ma=0.7);
y=0.073420x4-0.454691x3+1.120428x2-1.528388x+1.407926,（Ma=0.8）；y=0.073420x4 -0.454691x3 +1.120428x2 -1.528388x+1.407926, (Ma=0.8);
y=0.063518x4-0.403093x3+1.024408x2-1.453513x+1.407989,（Ma=0.9）；y=0.063518x4 -0.403093x3 +1.024408x2 -1.453513x+1.407989, (Ma=0.9);
y=0.063518x4-0.403093x3+1.024408x2-1.453513x+1.424103,（Ma=1.0）；y=0.063518x4 -0.403093x3 +1.024408x2 -1.453513x+1.424103, (Ma=1.0);
y=0.055502x4-0.360610x3+0.943630x2-1.388740x+1.422182,（Ma=1.1）；y=0.055502x4 -0.360610x3 +0.943630x2 -1.388740x+1.422182, (Ma=1.1);
y=0.055502x4-0.360610x3+0.943630x2-1.388740x+1.444153,（Ma=1.2）。y=0.055502x4 -0.360610x3 +0.943630x2 -1.388740x+1.444153, (Ma=1.2).
其中，x为气源压力，单位MPa，y为阀门开度比。下一步，根据上述离散点，结合试验样本进行数字建模，获取“阀门开度-气源压力-马赫数”关系模型：Among them, x is the air source pressure, unit MPa, and y is the valve opening ratio. Next, according to the above discrete points, digital modeling is carried out in combination with the test samples to obtain the "valve opening-air source pressure-Mach number" relationship model:
其中，k1～k4为气源压力次方系数，为常数项修正系数。Among them, k1 ~ k4 are the power coefficients of the gas source pressure, is the constant correction coefficient.
另外，需要说明的是，上述关系是在气动设备在小阻塞度（1%以内）情况下经实际吹风测试所得，当阻塞度增大时上述关系会有所变化，一般需乘上一个比例因子，具体数值与试验模型的实际情况有关。预置阀门开度曲线如图4所示。In addition, it should be noted that the above relationship is obtained through actual blowing test of pneumatic equipment under small blockage (within 1%). When the blockage increases, the above relationship will change. Generally, a proportional factor needs to be multiplied. The specific value is related to the actual situation of the test model. The preset valve opening curve is shown in Figure 4.
下一步，上述的精调步骤，采用误差分段PID控制方法进行马赫数控制，并利用PID参数自整定，以此可以提高阀门开度调节的速度。误差分段PID是基于传统PID的一种智能算法，PID参数整定主要由三个参数组成，Kp（P参数）、Ki（I参数）和Kd（D参数）。比例系数Kp的作用是加快系统的响应速度，提高系统的调节精度。Kp越大，系统的响应速度越快，系统的调节精度越高，但是容易产生超调，甚至会使系统不稳定。Kp取值过小，则会降低调节精度，使响应速度缓慢，从而延长调节时间，使系统静态、动态特性变差；积分作用系数Ki的作用是消除系统的静态误差。Ki越大，系统的静态误差消除的越快，但是Ki过大，在响应过程的初期会产生积分饱和的现象，从而引起响应过程的较大超调。若Ki过小，将使系统静态误差难以消除，影响系统的调节精度；微分系数Kd的作用是改善系统的动态特性，其作用主要是在响应过程中抑制偏差向任何方向的变化，对偏差变化进行提前预报。但是kd过大，会使响应过程提前制动，从而延长调节时间，而且会降低系统的抗干扰性。Next, in the above-mentioned fine-tuning step, the error segmented PID control method is used for Mach number control, and the PID parameter self-tuning is used to increase the speed of valve opening adjustment. Error segmented PID is an intelligent algorithm based on traditional PID. The PID parameter tuning mainly consists of three parameters, Kp (P parameter), Ki (I parameter) and Kd (D parameter). The role of the proportional coefficient Kp is to speed up the response speed of the system and improve the adjustment accuracy of the system. The larger the Kp, the faster the response speed of the system and the higher the adjustment accuracy of the system, but it is easy to produce overshoot and even make the system unstable. If the Kp value is too small, the adjustment accuracy will be reduced, the response speed will be slow, thereby extending the adjustment time and making the static and dynamic characteristics of the system worse; the role of the integral action coefficient Ki is to eliminate the static error of the system. The larger the Ki, the faster the static error of the system is eliminated, but if Ki is too large, the integral saturation phenomenon will occur in the early stage of the response process, thereby causing a large overshoot of the response process. If Ki is too small, it will be difficult to eliminate the static error of the system, affecting the adjustment accuracy of the system; the role of the differential coefficient Kd is to improve the dynamic characteristics of the system, and its main function is to suppress the change of the deviation in any direction during the response process and to predict the deviation change in advance. However, if kd is too large, the response process will be braked in advance, thereby extending the adjustment time and reducing the anti-interference ability of the system.
依据PID参数在调节阀门控制流场过程中，反应系统性能的两个参数是系统误差e和误差变化率Δe。首先，规定一个误差极限值Mmax、误差较大值Mmid以及误差较小值Mmin，当∣e∣>Mmax时，说明误差的绝对值已经很大，无论误差变化趋势如何，均须考虑控制器的输入应按最大（或最小）输出，以达到迅速调整误差的效果，使误差绝对值以最大的速度减小。此时，相当于实施开环控制。当e*Δe>0时，说明马赫数误差在朝误差绝对量增大方向变化，此时，如果∣e∣>Mmid，说明误差也较大，可考虑由控制器实施较强的控制作用，以达到扭转误差绝对值向减小的方向变化，并迅速减小误差的绝对值。此时如果∣e∣<Mmid，说明尽管误差是向绝对值增大的方向变化，但是误差绝对值本身并不是很大，可以考虑控制器实施一般的控制作用，只需要扭转误差的变化趋势，使其向误差绝对值减小的方向变化即可。当e*Δe<0时，说明误差在朝向误差绝对值减小的方向变化。如果此时误差的绝对值较大，大于Mmin，可以考虑实施较强控制作用。如果此时误差绝对值较小，可以考虑实施较弱控制作用。当∣e∣<Mmin时，说明误差绝对值很小，此时加入积分，减小静态误差。According to the PID parameters, in the process of adjusting the valve control flow field, the two parameters that reflect the system performance are the system error e and the error change rate Δe. First, an error limit value Mmax, a larger error value Mmid, and a smaller error value Mmin are specified. When |e|>Mmax, it means that the absolute value of the error is already very large. Regardless of the error change trend, it is necessary to consider that the controller input should be output at the maximum (or minimum) level to achieve the effect of quickly adjusting the error and reduce the absolute value of the error at the maximum speed. At this time, it is equivalent to implementing open-loop control. When e*Δe>0, it means that the Mach number error is changing in the direction of increasing the absolute amount of the error. At this time, if |e|>Mmid, it means that the error is also large. It can be considered that the controller implements a stronger control action to achieve the direction of reversing the absolute value of the error to decrease and quickly reduce the absolute value of the error. At this time, if |e|<Mmid, it means that although the error is changing in the direction of increasing the absolute value, the absolute value of the error itself is not very large. The controller can be considered to implement a general control action, which only needs to reverse the trend of the error change and change it in the direction of decreasing the absolute value of the error. When e*Δe<0, it means that the error is changing in the direction of decreasing the absolute value of the error. If the absolute value of the error is large and greater than Mmin, a stronger control effect can be considered. If the absolute value of the error is small, a weaker control effect can be considered. When |e|<Mmin, it means that the absolute value of the error is very small. At this time, integration is added to reduce the static error.
本设备流场控制根据马赫数误差Et（即e=Et时）（目标马赫数与实际马赫数的当前差值）的大小进行分段控制为：The flow field control of this equipment is segmented according to the size of the Mach number error Et (i.e. when e=Et) (the current difference between the target Mach number and the actual Mach number):
当∣Et∣≥0.1，取较大的第1组PID控制参数；When |Et|≥0.1, take the larger first group of PID control parameters;
当0.06≤∣Et∣＜0.1，取较大的第2组PID控制参数；When 0.06≤|Et|＜0.1, take the larger second group of PID control parameters;
当0.04≤∣Et∣＜0.06，取第3组PID控制参数；When 0.04≤|Et|＜0.06, take the third group of PID control parameters;
当0.02≤∣Et∣＜0.04，取第4组PID控制参数；When 0.02≤|Et|＜0.04, take the fourth group of PID control parameters;
当0.002≤∣Et∣＜0.02，取第5组PID控制参数；When 0.002≤|Et|＜0.02, take the fifth group of PID control parameters;
当∣Et∣<0.002，取较小的第6组PID控制参数。When |Et|<0.002, take the smaller sixth group of PID control parameters.
根据误差所处阶段以及误差变化趋势，对上述PID参数各组内PID控制参数作二次调整：According to the stage of the error and the error change trend, make secondary adjustments to the PID control parameters in each group of the above PID parameters:
在实际马赫数从0到目标马赫数期间，取较大的P参数（第1组）；在之后马赫数误差|Et|逐渐变大期间，取较大的P参数（如第1或第2组）；在马赫数误差|Et|逐渐变小期间，取较小的P参数（如第5或第6组）。参见附图5，在马赫数响应曲线的OA段，取较大的P参数，使实际马赫数快速逼近设定马赫数；在AB、CD段，误差有增大的趋势，即Et×ΔEt>0（其中，Et为当前马赫数误差，ΔEt为当前马赫数误差与上一时刻马赫数误差的差量），此时取较大的P参数；在BC、DE段，当误差有减小的趋势，即Et×ΔEt<0，此时取较小的P参数。当|Et|<εM（测控试验周期内马赫数偏移量）时表明在测控试验周期内较目标马赫数静态误差难以消除，必须调整较大的I参数（如第1或第2组）以消除静差。During the period when the actual Mach number changes from 0 to the target Mach number, a larger P parameter (group 1) is taken; during the period when the Mach number error |Et| gradually increases, a larger P parameter (such as group 1 or group 2) is taken; during the period when the Mach number error |Et| gradually decreases, a smaller P parameter (such as group 5 or group 6) is taken. Referring to Figure 5, in the OA section of the Mach number response curve, a larger P parameter is taken to make the actual Mach number quickly approach the set Mach number; in the AB and CD sections, the error tends to increase, that is, Et×ΔEt>0 (where Et is the current Mach number error, and ΔEt is the difference between the current Mach number error and the Mach number error at the previous moment), at this time a larger P parameter is taken; in the BC and DE sections, when the error tends to decrease, that is, Et×ΔEt<0, a smaller P parameter is taken. When |Et|<εM (Mach number offset within the measurement and control test cycle), it indicates that the static error relative to the target Mach number within the measurement and control test cycle is difficult to eliminate, and a larger I parameter (such as the first or second group) must be adjusted to eliminate the static error.
进一步考察变量|ΔEt/Et|的大小对PID参数进行三次整定，当|ΔEt/Et|>ΔM（设定的马赫数误差变化斜率），则表明误差变化较剧烈，此时视误差变化的方向（减小或增大），改变PID控制参数的值（误差减小即减小PID控制参数的值，误差增大即增大PID控制参数的值），以取得好的控制效果。Further investigation of the size of the variable |ΔEt/Et| led to three adjustments of the PID parameters. When |ΔEt/Et|>ΔM (the set slope of the Mach number error change), it indicates that the error changes dramatically. At this time, depending on the direction of the error change (decrease or increase), the value of the PID control parameter is changed (the error decreases, the value of the PID control parameter is reduced, and the error increases, the value of the PID control parameter is increased) to achieve a good control effect.
根据以上PID参数值，代入PID计算公式，Ua=Kp*Et+Ki*Eea；（Ua：PID输出量EEa:偏差累积量）。同时，根据当前偏差与目标马赫数比值，对PID输出量进行限制，避免调节量过大，导致系统异常。According to the above PID parameter values, substitute them into the PID calculation formula, Ua=Kp*Et+Ki*Eea; (Ua: PID output EEa: deviation accumulation). At the same time, according to the ratio of the current deviation to the target Mach number, the PID output is limited to avoid excessive adjustment and cause system abnormality.
当Et/AimM（目标马赫数）>0.01，如果Ua>0.3，则Ua=0.3，如果UA<-0.3，则Ua=-0.3；When Et/AimM (target Mach number)>0.01, if Ua>0.3, then Ua=0.3, if UA<-0.3, then Ua=-0.3;
当0.01≥Et/AimM>0.005，如果Ua>0.25，则Ua=0.25，如果UA<-0.25，则Ua=-0.25；When 0.01≥Et/AimM>0.005, if Ua>0.25, then Ua=0.25, if UA<-0.25, then Ua=-0.25;
当0.005≥Et/AimM>0.0025，如果Ua>0.2，则Ua=0.2，如果UA<-0.2，则Ua=-0.2；When 0.005≥Et/AimM>0.0025, if Ua>0.2, then Ua=0.2, if UA<-0.2, then Ua=-0.2;
以此类推。And so on.
通过以上控制算法，自动对PID参数进行整定，外部只需要给定一组PID参数，即可实现各个马赫数精确控制。Through the above control algorithm, the PID parameters are automatically adjusted. Only one set of PID parameters needs to be given externally to achieve precise control of various Mach numbers.
本实施例中，通过对M0.3，M0.4，M0.5，M0.6，M0.7，M0.8，M0.85，M0.9，M0.95，M1.0，M1.05，M1.1，M1.15，M1.2工况进行预置阀门开度、控制参数调试，并对流场气动参数进行测试与验证，测试结果见下表：In this embodiment, the valve opening and control parameter debugging are performed on the working conditions of M0.3, M0.4, M0.5, M0.6, M0.7, M0.8, M0.85, M0.9, M0.95, M1.0, M1.05, M1.1, M1.15, and M1.2, and the flow field aerodynamic parameters are tested and verified. The test results are shown in the following table:
表1 跨声速试验各马赫数下调试测试表Table 1 Debugging test table at various Mach numbers in transonic test
本实施例中，超声速试验段采用1#、2#、3#、4#、5#、6#固定型面喷管进行试验，对应试验马赫数分别为1.5、1.7991、2.0412、2.2540、2.5474、3.0130（此为本实施例的试验取值，也可是其他值）。通过通气调试，给出在各喷管下稳定流场建立所对应的开车参数（稳定段总压（或稳定段总压与引射压力）），并获得控制相应稳定段总压（或稳定段总压与引射压力）时合适的控制方式与控制参数，以使得控制精度满足要求，同时稳定所需的过渡时间较少。In this embodiment, the supersonic test section uses 1#, 2#, 3#, 4#, 5#, and 6# fixed-profile nozzles for testing, and the corresponding test Mach numbers are 1.5, 1.7991, 2.0412, 2.2540, 2.5474, and 3.0130, respectively (these are the test values of this embodiment, and other values may also be used). Through ventilation debugging, the start-up parameters (stable section total pressure (or stable section total pressure and ejection pressure)) corresponding to the establishment of a stable flow field under each nozzle are given, and the appropriate control method and control parameters when controlling the corresponding stable section total pressure (or stable section total pressure and ejection pressure) are obtained, so that the control accuracy meets the requirements, and the transition time required for stability is short.
超声速试验度马赫数控制以稳定段总压（或稳定段总压+引射压力）为受控量，通过对主调压阀的开度调节实现稳定段总压控制，必要时，通过对引射调压阀的开度调节实现引射压力控制。与跨声速试验段相同，气动设备总压控制方式同样为预置阀门开度+阀门开度精调的控制调节方式，即总压的控制方法包括两个子步骤，分别为：a.根据设定的气源压力和总压（或引射压力），从预配置的第二预置阀门开度-气源压力关系（第二关系）中匹配出预置阀门开度。b.对阀门开度进行精调。此处的第二预置阀门开度-气源压力关系的获得方法与第一预置阀门开度-气源压力关系大体相同，区别在于各喷管的马赫数是确定的，即第二预置阀门开度-气源压力关系通过以下方法获得：The Mach number control of the supersonic test section uses the total pressure of the stable section (or the total pressure of the stable section + the ejection pressure) as the controlled quantity. The total pressure control of the stable section is achieved by adjusting the opening of the main pressure regulating valve. If necessary, the ejection pressure control is achieved by adjusting the opening of the ejection pressure regulating valve. Similar to the transonic test section, the total pressure control method of the pneumatic equipment is also a control and adjustment method of preset valve opening + valve opening fine adjustment, that is, the total pressure control method includes two sub-steps, namely: a. According to the set air source pressure and total pressure (or ejection pressure), match the preset valve opening from the pre-configured second preset valve opening-air source pressure relationship (second relationship). b. Fine-tune the valve opening. The method for obtaining the second preset valve opening-air source pressure relationship here is roughly the same as the first preset valve opening-air source pressure relationship. The difference is that the Mach number of each nozzle is determined, that is, the second preset valve opening-air source pressure relationship is obtained by the following method:
在喷管就位后，在安全总压范围以内，逐步增加主调压阀/引射阀开度，实时记录气源压力Pt、调压阀开度比S/Smax和稳定段总压等，根据这些记录的数据，由流量公式，即可计算出在各喷管对应的马赫数下，主调压阀/引射阀预置开度与气源压力间的理论关系。After the nozzle is in place, within the safe total pressure range, gradually increase the opening of the main pressure regulating valve/injection valve, and record the gas source pressure Pt, the pressure regulating valve opening ratio S/Smax and the total pressure in the stable section in real time. Based on these recorded data, the theoretical relationship between the preset opening of the main pressure regulating valve/injection valve and the gas source pressure at the Mach number corresponding to each nozzle can be calculated by the flow formula.
上述的精调步骤，采用误差分段PID控制算法进行总压控制，并利用PID参数自整定。该步骤对于主调压阀和引射阀有所区别，对于主调压阀，该步骤包括：The above-mentioned fine adjustment step adopts the error segmented PID control algorithm to control the total pressure and uses the PID parameter self-tuning. This step is different for the main pressure regulating valve and the ejector valve. For the main pressure regulating valve, this step includes:
根据总压误差Ep（即e=Ep时）（目标总压Po与实际总压的差值）的大小进行分段控制：According to the total pressure error Ep (i.e. when e=Ep) (the difference between the target total pressure Po and the actual total pressure), segmented control is performed:
当∣Ep/Po∣>0.02，取较大的第1组PID控制参数；When |Ep/Po|>0.02, take the larger PID control parameter of the first group;
当0.005≤∣Ep/Po∣<0.02，取较大的第2组PID控制参数；When 0.005≤|Ep/Po|<0.02, take the larger second group of PID control parameters;
当0.0035≤∣Ep/Po∣<0.005，取第3组PID控制参数；When 0.0035≤|Ep/Po|<0.005, take the third group of PID control parameters;
当0.0015≤∣Ep/Po∣<0.0035，取第4组PID控制参数；When 0.0015≤|Ep/Po|<0.0035, take the fourth group of PID control parameters;
当∣Ep/Po∣<0.0015，取较小的第5组PID控制参数。When |Ep/Po|<0.0015, take the smaller fifth group of PID control parameters.
根据误差所处阶段以及误差变化趋势，对上述PID参数各组内PID控制参数作二次调整：According to the stage of the error and the error change trend, make secondary adjustments to the PID control parameters in each group of the above PID parameters:
在实际总压从0到目标总压期间，取较大的P参数（第1组）；在之后总压误差|Ep|逐渐变大期间，取较大的P参数（如第1组）；在总压误差|Ep|逐渐变小期间，取较小的P参数（如第5组）。总压的变化规律与附图5中马赫数变化规律相同，因此，参照附图5，在总压响应曲线的OA段，取较大的P参数，使实际总压快速逼近设定总压；在AB、CD段，误差有增大的趋势，即Ep×ΔEp>0（其中，Ep为当前总压与目标值误差，ΔEp为当前总压误差较上一时刻总压误差的差量），此时取较大的P参数，当误差有减小的趋势，即Ep×ΔEp<0，此时取较小的P参数；当|Ep|<εP（测控试验周期内总压偏移量）时，表明在测控试验周期内较目标总压静态误差难以消除，必须调整较大的I参数以消除静差。During the period when the actual total pressure changes from 0 to the target total pressure, a larger P parameter (Group 1) is taken; during the period when the total pressure error |Ep| gradually increases, a larger P parameter (such as Group 1) is taken; during the period when the total pressure error |Ep| gradually decreases, a smaller P parameter (such as Group 5) is taken. The variation law of the total pressure is the same as the variation law of the Mach number in Figure 5. Therefore, referring to Figure 5, in the OA section of the total pressure response curve, a larger P parameter is taken to make the actual total pressure quickly approach the set total pressure; in the AB and CD sections, the error tends to increase, that is, Ep×ΔEp>0 (where Ep is the error between the current total pressure and the target value, and ΔEp is the difference between the current total pressure error and the total pressure error at the previous moment), at this time a larger P parameter is taken; when the error tends to decrease, that is, Ep×ΔEp<0, a smaller P parameter is taken; when |Ep|<εP (total pressure offset within the measurement and control test cycle), it indicates that the static error of the total pressure relative to the target within the measurement and control test cycle is difficult to eliminate, and a larger I parameter must be adjusted to eliminate the static error.
同时，考察变量|ΔEp/Ep|的大小对PID参数进行整定，当|ΔEp/Ep|>ΔPo（设定的总压误差变化斜率），则表明误差变化较剧烈，此时视误差变化的方向（减小或增大），改变PID控制参数的值（误差减小即减小PID控制参数的值，误差增大即增大PID控制参数的值），以取得好的控制效果。At the same time, the size of the variable |ΔEp/Ep| is examined to adjust the PID parameters. When |ΔEp/Ep|>ΔPo (the set total pressure error change slope), it indicates that the error changes more dramatically. At this time, depending on the direction of the error change (decrease or increase), the value of the PID control parameter is changed (the error decreases, the value of the PID control parameter is reduced, and the error increases, the value of the PID control parameter is increased) to obtain a good control effect.
引射压力控制方法与总压控制方法的精调步骤类似，其包括：The fine adjustment steps of the injection pressure control method are similar to those of the total pressure control method, which include:
根据引射压力误差Epd（目标引射压力Pd与实际引射压力的差值）的大小进行分段控制，考虑到引射压力控制精度要求相对较低，同时引射管路相对简洁，压力稳定较容易，因此对误差Epd的分段只按照四段进行划分：The injection pressure error Epd (the difference between the target injection pressure Pd and the actual injection pressure) is controlled in sections. Considering that the injection pressure control accuracy requirement is relatively low, and the injection pipeline is relatively simple and the pressure is easy to stabilize, the error Epd is divided into four sections:
当∣Epd/Pd∣>0.01，取较大的第1组PID控制参数；When |Epd/Pd|>0.01, take the larger first group of PID control parameters;
当0.008≤∣Epd/Pd∣<0.01，取较大的第2组PID控制参数；When 0.008≤|Epd/Pd|<0.01, take the larger second group of PID control parameters;
当0.003≤∣Epd/Pd∣<0.008，取第3组PID控制参数；When 0.003≤|Epd/Pd|<0.008, take the third group of PID control parameters;
当∣Epd/Pd∣<0.003，取较小的第4组PID控制参数。When |Epd/Pd|<0.003, take the smaller fourth group of PID control parameters.
根据误差所处阶段以及误差变化趋势，对上述PID参数各组内PID控制参数作二次调整，具体调节方法与总压控制的调节方法相似，将其中的总压替换为引射压力即可。According to the stage of the error and the error change trend, the PID control parameters in each group of the above PID parameters are adjusted secondary. The specific adjustment method is similar to that of the total pressure control, and the total pressure is replaced by the injection pressure.
通过试验观察，试验通风后，在流场建立之前，马赫数会来回震荡。如图6所示，假设目标马赫数设定为0.8，阀门开度保持预设值不变，快速阀打开后10S内，马赫数来回震荡，10S后马赫数趋于稳定。根据以上现象得知，快速阀打开后10S区间内，反馈的马赫数并不是主调压阀当前位置马赫数真实反馈，若基于此变化的马赫数进行快速调节，将导致在10S后与阀门预设值有较大偏差。PID控制需消除目标值与实际值之间的偏差，重新开始计算调节，造成调节时间加长，并且阀门预置也将失去原有的作用（阀门预置准确，将减少调节时间）。Through experimental observation, after the test ventilation, before the flow field is established, the Mach number will oscillate back and forth. As shown in Figure 6, assuming that the target Mach number is set to 0.8, the valve opening remains unchanged at the preset value, and the Mach number oscillates back and forth within 10 seconds after the quick valve is opened, and the Mach number tends to stabilize after 10 seconds. According to the above phenomenon, within the 10S interval after the quick valve is opened, the feedback Mach number is not the true feedback of the Mach number of the current position of the main pressure regulating valve. If a rapid adjustment is made based on this changing Mach number, it will lead to a large deviation from the valve preset value after 10S. PID control needs to eliminate the deviation between the target value and the actual value, and restart the calculation and adjustment, which will cause the adjustment time to be longer, and the valve preset will also lose its original function (accurate valve preset will reduce the adjustment time).
为此，通过以下方法来解决马赫数在流场建立初期（预定时间内）来回震荡的问题：To this end, the following methods are used to solve the problem of Mach number oscillation in the early stage of flow field establishment (predetermined time):
（1）检测马赫数偏差变化率，当连续多个周期（设定周期数）内，马赫数变化趋于平缓（通过设定的变化率的阈值判定，多个周期均低于设定阈值，则视为平缓）后再投入PID调节（即利用PID参数进行闭环控制），阀门PID控制基于当前稳定准确的马赫数进行调节，能够更加快速、准确的实现马赫数闭环控制，提高马赫数控制精度。(1) Detect the change rate of the Mach number deviation. When the Mach number changes gradually over multiple consecutive cycles (a set number of cycles), the PID adjustment (i.e., closed-loop control using PID parameters) is implemented after the Mach number changes gradually over multiple consecutive cycles (a set number of cycles) (determined by a set change rate threshold, if multiple cycles are lower than the set threshold, then it is considered to be gradual). The valve PID control is adjusted based on the current stable and accurate Mach number, which can achieve Mach number closed-loop control more quickly and accurately, thereby improving the Mach number control accuracy.
（2）PID控制加入斜率判断，考察变量|ΔEp/Ep|的大小对PID参数进行整定，当|ΔEp/Ep|>ΔPo，则表明误差变化较剧烈，此时视误差变化的（趋势）方向（减小或增大），改变PID控制参数的值（同上），以取得好的控制效果。(2) Slope judgment is added to PID control. The size of the variable |ΔEp/Ep| is examined to adjust the PID parameters. When |ΔEp/Ep|>ΔPo, it indicates that the error changes more dramatically. At this time, depending on the (trend) direction of the error change (decrease or increase), the value of the PID control parameter is changed (same as above) to achieve a good control effect.
同时当误差有减小的趋势，即Ep×ΔEp<0，此时取PID参数中较小一组P参数（如第6组）；当|Ep|<εP，则取PID参数中最大的一组I参数（即第1组Ki）以消除静差。At the same time, when the error tends to decrease, that is, Ep×ΔEp<0, a smaller group of P parameters in the PID parameters (such as the 6th group) is taken; when |Ep|<εP, the largest group of I parameters in the PID parameters (that is, the 1st group Ki) is taken to eliminate the static error.
气动设备正式投产，进行模型试验时，需要考虑运行的经济性，即平均每车次耗气量要尽可能小，亦即需尽量提高气动设备带模型试验时的试验效率。采用下述方法解决气动设备试验效率问题：When the pneumatic equipment is officially put into production and the model test is carried out, the economic efficiency of operation needs to be considered, that is, the average gas consumption per vehicle should be as small as possible, that is, the test efficiency of the pneumatic equipment with model test needs to be improved as much as possible. The following methods are used to solve the problem of pneumatic equipment test efficiency:
（1）控制算法与控制参数优化，(1) Control algorithm and control parameter optimization,
如前所述，采用了PID参数自整定算法，根据误差范围、误差变化率等多特征值作为依据，对控制参数进行多模态、仿人预测整定，提高了流场稳定速度。As mentioned above, the PID parameter self-tuning algorithm is adopted. Based on multiple characteristic values such as error range and error change rate, the control parameters are multi-modal and human-like predictive tuning to improve the flow field stabilization speed.
（2）控制流程优化，(2) Control process optimization,
在不影响安全的情况下，将首阶梯预置置于气动设备快速开启之前或流场首次建立立即进行；在关车时，一旦模型攻角回到不影响安全的角度范围，立即关闭快速阀，节省气源；测控系统实现全自动判稳、采集、应答流程，避免人工参与造成的吹风时间延长。Without affecting safety, the first-step preset is placed before the pneumatic equipment is quickly opened or immediately after the flow field is first established; when shutting down the machine, once the model attack angle returns to the angle range that does not affect safety, the quick valve is immediately closed to save gas source; the measurement and control system realizes fully automatic stability judgment, collection, and response processes to avoid extended blowing time caused by manual participation.
（3）缩短无效等待时间，(3) Shorten the invalid waiting time,
缩短控制周期（0.1s），以减少流场判稳所需时间；提高攻角运行速度（5°/s），缩短大范围变攻角以及从大攻角回零所需时间；优化测控系统间通讯，缩短二者间通讯等待时间（小于50ms）。Shorten the control cycle (0.1s) to reduce the time required for flow field stabilization; increase the angle of attack speed (5°/s) to shorten the time required for large-scale angle of attack changes and returning to zero from large angles of attack; optimize communication between measurement and control systems and shorten the communication waiting time between the two (less than 50ms).
（4）变阶梯时的预测控制，(4) Predictive control when changing steps,
在模型变阶梯时，根据其变化方向以及对流场的影响趋势，提前施加相应的控制，以便尽量抵消由于攻角变化对流场的影响，减小调节时间。When the model changes stepwise, corresponding control is applied in advance according to its changing direction and the trend of its influence on the flow field, so as to offset the influence of the change of the angle of attack on the flow field as much as possible and reduce the adjustment time.
本发明并不局限于前述的具体实施方式。本发明扩展到任何在本说明书中披露的新特征或任何新的组合，以及披露的任一新的方法或过程的步骤或任何新的组合。The present invention is not limited to the above-mentioned specific embodiments, but extends to any new features or any new combination disclosed in this specification, as well as any new method or process steps or any new combination disclosed.
| Application Number | Priority Date | Filing Date | Title |
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| CN202411300686.6ACN118817234B (en) | 2024-09-18 | 2024-09-18 | Pneumatic equipment measurement and control system |
| Application Number | Priority Date | Filing Date | Title |
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| CN202411300686.6ACN118817234B (en) | 2024-09-18 | 2024-09-18 | Pneumatic equipment measurement and control system |
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| CN118817234B CN118817234B (en) | 2024-11-22 |
| Application Number | Title | Priority Date | Filing Date |
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| CN202411300686.6AActiveCN118817234B (en) | 2024-09-18 | 2024-09-18 | Pneumatic equipment measurement and control system |
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