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Overall Solution of Control System for 3.6MW Doubly-fed Motor Test Bench
Release time:
2022-08-06
This test bench is a 3.6MW doubly-fed motor test bench built by the company. Its entire system consists of three relatively independent measurement and control subsystems: no-load test bench, type test bench and factory test bench. Each subsystem includes the control and monitoring of high and low voltage switchgear related to the test bench line, frequency converter control and monitoring, power measurement system, temperature and oil and water circuit measurement and monitoring system, etc.
Design a comprehensive monitoring station, in which the status of system lines and equipment can be centrally monitored to form the overall line monitoring and control function of the test station; Install a data server in the comprehensive monitoring station to provide database services for each subsystem; Install a set of video monitoring system in the comprehensive monitoring station to comprehensively monitor the cameras in the equipment area of each subsystem and the tested equipment area; Configure two printers, provide printing services for each subsystem. The measurement and control equipment and workstations used in this solution are interconnected through on-site Gigabit Ethernet, and each control workstation and test workstation are peer-to-peer structure, and the function is only different in the running software. That is, by running different software, the computer can be used as a control station or test computer.
1. 3.6MW double-fed motor test bench control system
3.6MW double-fed motor test bench control system topology diagram
control system function
1, monitoring operation station can display the simulation of field equipment in real time, intuitively, clearly and dynamically;
The system can quickly and flexibly select working conditions, and configure the test equipment according to the requirements of the tested object for the system. Once confirmed, the system automatically inspects the equipment corresponding to the working condition.
-3, realize the setting of various parameters of the test system, including internal parameters and various given values;
-4, carry out communication control and status and data inspection of the test frequency converter;
-5, for each electrical switch of high and low voltage AC electrical appliances, digital monitoring, interlocking and alarming of analog and thermal quantities. The system provides a variety of fault handling methods and alarm management. It can complete the dynamic monitoring of the running state of the controlled object of the test station in real time, accurately and effectively, and alarm protection for equipment failure. The control system completes the control and status monitoring of high and low voltage switchgear, power grid monitoring (10kV power grid, 6 90V 50Hz power grid, 660Hz), control and status monitoring of frequency converter, control and status monitoring of oil and water circuit system.
It adopts a distributed system structure, the PLC selects Siemens S7-300 series, the CPU selects CPU315-2F/DP fail-safe products, and expands the necessary input and output modules for connecting external devices.
The control and monitoring of the system is divided into high and low voltage control cabinet area and thermal area, and ET200 distributed I/0 sub-station is selected for the design of each area. The ET200M distributed I/O station of the field control station communicates with the S7-300 central controller in real time through PROFIBUS-DP field bus. Its main functions are: collecting field I/O signals (digital and analog), transmitting field digital or analog signals to the central control station through the I/O signal interface module of ET200M, and sending control signals sent by the central controller to field devices to complete device control. The frequency converters (drive converter, rotor converter, test power converter) at each test bench in the system communicate with the S7-300 central controller in real time via PROFIBUS-DP field bus.
. The integrated relay device communicates in real time with the S7-300 central controller via the ModBus bus. Communication between the monitoring master station installed in the system monitoring station and the PLC through industrial Ethernet;
(temperature monitoring sub-stations of each test bench and monitoring master station are interconnected through Ethernet of the test system for fast data exchange, and the power measurement and distributed measurement data, power, etc. obtained by each monitoring sub-station are centrally monitored and displayed on the monitoring master station through fast data exchange.
2. 3.6MW doubly-fed motor test bench system monitoring main station and monitoring sub-station
This system designs a set of system monitoring station. The monitoring main station is installed in the monitoring station to complete system configuration and monitoring functions. The monitoring main station and the monitoring sub-stations of each test bench communicate with the monitoring main station by OPC.
The monitoring main station displays the simulation diagrams of each field equipment of the system in real time, intuitively and dynamically, digital display of each analog monitoring value. A monitoring sub-station (control computer) is designed and installed on each test bench. The monitoring sub-station displays the dynamic simulation diagram of the field equipment related to the test bench and the test project, and the digital display of the monitoring value of each analog quantity. After authorization, the monitoring sub-station can have the same authority as the main station, both the monitoring sub-station can perform all the functions of the main station, control and monitor all the equipment of the system.
1. Distributed I/O
in high and low voltage areas completes the control of high and low voltage switchgear according to the control signals issued by the central controller;
completes the contact signal monitoring of high and low voltage switchgear;
The analog input module completes the signal collection of sensors (transmitters) for high and low voltage power grid monitoring (10kV power grid, 690V 50Hz power grid, 690V 60Hz).
2, thermal zone distributed I/O
to complete the oil and water pressure, flow control and data acquisition. The system monitoring master station completes the monitoring function of the oil and water circuit. The oil and water circuit data is processed in the system control software as a necessary condition for system operation, and alarms and protection actions are generated through threshold setting. The oil and water circuit data is recorded to the database according to the test requirements.
Safety design of monitoring software for 3. 3.6MW doubly-fed motor test bench
The monitoring software is designed to automatically or manually configure the system, and manual is preferred. In addition to monitoring the switching status of high and low voltage switch cabinets, the monitoring software also monitors analog quantities such as 10kV power grid and 690V power grid (50Hz, 60Hz). In the software design, through the monitoring of switch quantity and analog quantity, the switch from 10kV incoming line to the input switch of each frequency converter is interlocked in stages, that is, the next switch is allowed to be closed only if the output voltage of the previous level meets the design requirements. For the tested motor and test items that require the oil and water system to work, the normal operation of the oil and water system (including the flow rate, pressure, etc. that meet the requirements of the tested product and accompanying equipment) is the prerequisite for the system to start. If the state exceeds the operating conditions during operation, the alarm and automatic/manual shutdown procedures will be entered according to the preset settings. The monitoring sub-station in each test bench can only operate the equipment related to the test of the test bench. Under authorized circumstances, the monitoring sub-station has the same authority as the main station and can operate all equipment.
4. 3.6MW doubly-fed motor test bench protection and fault alarm
1. Self-monitoring and diagnosis
. Monitoring and testing software routines continuously check the normality of the system. Faults of functions and boards/modules are output by text to the screen of the monitoring master station. A printout of the fault alert is also generated. The information is comprehensive enough so that the staff can understand the impact on the system, and it is also convenient for maintenance personnel to quickly implement fault analysis and repair.
2. Fault Treatment and Protection Shutdown
When a certain equipment fails, the system enters the fault treatment state according to the faulty equipment, fault type and preset fault treatment procedure. For faults that directly affect the safety of the system, the system automatically enters the emergency shutdown procedure and automatically completes the system emergency shutdown control process.
3. Operation Error Warning
When the operator performs manual operation, it violates the operation routine, and the monitoring software issues a warning in the monitoring main station or monitoring sub-station through text, and prompts the cause of the error.
4. Alarm and failure records
Record the equipment, type, time and other failure records that caused the failure, and form a record file.
Design a comprehensive monitoring station, in which the status of system lines and equipment can be centrally monitored to form the overall line monitoring and control function of the test station; Install a data server in the comprehensive monitoring station to provide database services for each subsystem; Install a set of video monitoring system in the comprehensive monitoring station to comprehensively monitor the cameras in the equipment area of each subsystem and the tested equipment area; Configure two printers, provide printing services for each subsystem. The measurement and control equipment and workstations used in this solution are interconnected through on-site Gigabit Ethernet, and each control workstation and test workstation are peer-to-peer structure, and the function is only different in the running software. That is, by running different software, the computer can be used as a control station or test computer.
1. 3.6MW double-fed motor test bench control system
3.6MW double-fed motor test bench control system topology diagram
control system function
1, monitoring operation station can display the simulation of field equipment in real time, intuitively, clearly and dynamically;
The system can quickly and flexibly select working conditions, and configure the test equipment according to the requirements of the tested object for the system. Once confirmed, the system automatically inspects the equipment corresponding to the working condition.
-3, realize the setting of various parameters of the test system, including internal parameters and various given values;
-4, carry out communication control and status and data inspection of the test frequency converter;
-5, for each electrical switch of high and low voltage AC electrical appliances, digital monitoring, interlocking and alarming of analog and thermal quantities. The system provides a variety of fault handling methods and alarm management. It can complete the dynamic monitoring of the running state of the controlled object of the test station in real time, accurately and effectively, and alarm protection for equipment failure. The control system completes the control and status monitoring of high and low voltage switchgear, power grid monitoring (10kV power grid, 6 90V 50Hz power grid, 660Hz), control and status monitoring of frequency converter, control and status monitoring of oil and water circuit system.
It adopts a distributed system structure, the PLC selects Siemens S7-300 series, the CPU selects CPU315-2F/DP fail-safe products, and expands the necessary input and output modules for connecting external devices.
The control and monitoring of the system is divided into high and low voltage control cabinet area and thermal area, and ET200 distributed I/0 sub-station is selected for the design of each area. The ET200M distributed I/O station of the field control station communicates with the S7-300 central controller in real time through PROFIBUS-DP field bus. Its main functions are: collecting field I/O signals (digital and analog), transmitting field digital or analog signals to the central control station through the I/O signal interface module of ET200M, and sending control signals sent by the central controller to field devices to complete device control. The frequency converters (drive converter, rotor converter, test power converter) at each test bench in the system communicate with the S7-300 central controller in real time via PROFIBUS-DP field bus.
. The integrated relay device communicates in real time with the S7-300 central controller via the ModBus bus. Communication between the monitoring master station installed in the system monitoring station and the PLC through industrial Ethernet;
(temperature monitoring sub-stations of each test bench and monitoring master station are interconnected through Ethernet of the test system for fast data exchange, and the power measurement and distributed measurement data, power, etc. obtained by each monitoring sub-station are centrally monitored and displayed on the monitoring master station through fast data exchange.
2. 3.6MW doubly-fed motor test bench system monitoring main station and monitoring sub-station
This system designs a set of system monitoring station. The monitoring main station is installed in the monitoring station to complete system configuration and monitoring functions. The monitoring main station and the monitoring sub-stations of each test bench communicate with the monitoring main station by OPC.
The monitoring main station displays the simulation diagrams of each field equipment of the system in real time, intuitively and dynamically, digital display of each analog monitoring value. A monitoring sub-station (control computer) is designed and installed on each test bench. The monitoring sub-station displays the dynamic simulation diagram of the field equipment related to the test bench and the test project, and the digital display of the monitoring value of each analog quantity. After authorization, the monitoring sub-station can have the same authority as the main station, both the monitoring sub-station can perform all the functions of the main station, control and monitor all the equipment of the system.
1. Distributed I/O
in high and low voltage areas completes the control of high and low voltage switchgear according to the control signals issued by the central controller;
completes the contact signal monitoring of high and low voltage switchgear;
The analog input module completes the signal collection of sensors (transmitters) for high and low voltage power grid monitoring (10kV power grid, 690V 50Hz power grid, 690V 60Hz).
2, thermal zone distributed I/O
to complete the oil and water pressure, flow control and data acquisition. The system monitoring master station completes the monitoring function of the oil and water circuit. The oil and water circuit data is processed in the system control software as a necessary condition for system operation, and alarms and protection actions are generated through threshold setting. The oil and water circuit data is recorded to the database according to the test requirements.
Safety design of monitoring software for 3. 3.6MW doubly-fed motor test bench
The monitoring software is designed to automatically or manually configure the system, and manual is preferred. In addition to monitoring the switching status of high and low voltage switch cabinets, the monitoring software also monitors analog quantities such as 10kV power grid and 690V power grid (50Hz, 60Hz). In the software design, through the monitoring of switch quantity and analog quantity, the switch from 10kV incoming line to the input switch of each frequency converter is interlocked in stages, that is, the next switch is allowed to be closed only if the output voltage of the previous level meets the design requirements. For the tested motor and test items that require the oil and water system to work, the normal operation of the oil and water system (including the flow rate, pressure, etc. that meet the requirements of the tested product and accompanying equipment) is the prerequisite for the system to start. If the state exceeds the operating conditions during operation, the alarm and automatic/manual shutdown procedures will be entered according to the preset settings. The monitoring sub-station in each test bench can only operate the equipment related to the test of the test bench. Under authorized circumstances, the monitoring sub-station has the same authority as the main station and can operate all equipment.
4. 3.6MW doubly-fed motor test bench protection and fault alarm
1. Self-monitoring and diagnosis
. Monitoring and testing software routines continuously check the normality of the system. Faults of functions and boards/modules are output by text to the screen of the monitoring master station. A printout of the fault alert is also generated. The information is comprehensive enough so that the staff can understand the impact on the system, and it is also convenient for maintenance personnel to quickly implement fault analysis and repair.
2. Fault Treatment and Protection Shutdown
When a certain equipment fails, the system enters the fault treatment state according to the faulty equipment, fault type and preset fault treatment procedure. For faults that directly affect the safety of the system, the system automatically enters the emergency shutdown procedure and automatically completes the system emergency shutdown control process.
3. Operation Error Warning
When the operator performs manual operation, it violates the operation routine, and the monitoring software issues a warning in the monitoring main station or monitoring sub-station through text, and prompts the cause of the error.
4. Alarm and failure records
Record the equipment, type, time and other failure records that caused the failure, and form a record file.
Comparison of different measurement methods
2022-08-16
2022-08-16
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