Available online at www.sciencedirect.com Available online at www.sciencedirect.com
Procedia Engineering
Procedia Engineering 00 (2011) 000–000 Procedia Engineering 15 (2011) 1061 – 1065 www.elsevier.com/locate/procedia
Advanced in Control Engineering and Information Science
Research and Implementation of Monitoring System for Injection Pump Durability Tester Xiao Chuna, Li Mingb, Hu Shanc zhang lijund,a * a
Xiao Chun, Wuhan University of Technology, Wuhan 430070, China b Li Ming, Wuhan University of Technology, Wuhan 430070, China
Abstract Taking the background of the durability test for high-pressure common rail injection pump which is made in the Bosch firm, we have designed the monitoring system of injection pump durability tester based on fieldbus control system (FCS) [1], [2]. Firstly, the paper total analyses the injection pump durability test. Then it mainly introduces the hardware of the monitoring system and puts forward configuration of the test. Finally we completed the software of the monitoring system based on the platform of Lab Windows/CVI. It improves the working efficiency greatly of the tester.
© 2011 Published by Elsevier Ltd. Open access under CC BY-NC-ND license. Selection and/or peer-review under responsibility of [CEIS 2011] Keywords: tester, injection pump, fieldbus, monitor, LabWindows/CVI;
1. Preface With the rapidly development of science and technology, the engine plays a more and more important role in this word. Specially, the diesel engine has been popularly applied in the variety of fields because of its low invest but high produce ability. People usually describe the oil spray system is the heart of diesel engine, and it’s nucleus is the injection pump, so the performance of injection pump is an important
* Xiao Chun. Tel.: 13871175863. E-mail address:
[email protected].
1877-7058 © 2011 Published by Elsevier Ltd. Open access under CC BY-NC-ND license. doi:10.1016/j.proeng.2011.08.196
1062 2
Xiao Chun / Procedia Engineering (2011) 1061 – 1065 Xiao Chun ，etetal/al.Procedia Engineering 0015 (2011) 000–000
indicator of diesel engine’s performance. Technique of high-pressure common rail injection systems reduces the emissions and noise, so the diesel engine fundamentally adopts this technique in domestic and international. The durability of the high-pressure common rail injection pump is the research topic of the diesel engine designer and producer in many countries. An important characteristic of the durability test is the test time too long, and common rail is always in high pressure when the injection pump works in the durability test. So we must supervise the tester on real time to make sure the tester safety, stabilize and healthy operation. To design an intelligent, safety and performance stabilization monitoring system for the injection pump durability tester is very meaningful. This paper designs a monitoring system of injection pump durability tester, which satisfies Europe standard Ⅲ, realizes the run-time process of the tester in the whole digital supervise and control, and completes the data exchange of real time through the Profibus interface， RS485 bus， distributed I/O, inverter and other equipments. 2. Total analysis the injection pump durability tester The injection pump is mainly composed of high pressure oil pumps, pressure sensors and electronic control unit (ECU). The main function of ECU is to control the oil of spray oil gun. The construction picture of high-Pressure common rail injection pump is shown in Fig 1. High pressure pump ECU
Common rail pipe
Sensor
Injector Fig. 1. The construction picture of high-Pressure common rail injection pump
The hydraulic system of injection pump durability tester (IPDT) has five compositions which are diesel and automobile oil circulatory system, diesel thermal exchange system, cooling and dirty oil to handle system and drive system. They assure the cyclic transformation progress of IPDT. According to the request of the monitoring system of IPDT, its simulative I/O signals are speed signal, liquid level signal, press signal, temperature signal and simulative I/O signals. The construction picture of Liquid force system of IPDT is shown in Fig 2 Diesel tank
Lubricating oil tank
Diesel pump
Lubricating oil pump
Diesel inlet channel Level gauge N TT0 Y Cooling Set oil Abandoned oil Y Contaminated oil pump
N
T>T0 Y Cooling
Abandoned oil Y Contaminated oil pump
Contaminated oil tank Fig. 2. The construction picture of Liquid force system of injection pump durability tester
N
Xiao Chun et al. // Procedia – 1065 Xiao Chun Procedia Engineering Engineering 15 00 (2011) (2011) 1061 000–000
3. The design of the monitoring system hardware 3.1. Construction of terminal bus system According to the craft request and characteristics of injection pump durability tester, the bus control system of the tester use CP5611 communication board card as the DP lord station. To complete the whole supervision of tester which combines with the industrial PC. The way not only save the PLC and cost, but still intensify the tight type of the control system. 3.2. Construction of bus terminal subsystem The construction of the bus terminal subsystem mainly includes the BeckHoff bus coupler and the selection of I/O terminal module. The subsystem of BeckHoff bus coupler not only raises the tight type of the control system, but reduces idle gateway and cut cost which uses modularization structure. The I/O terminals module is the important part of subsystem of bus, it uses terminals module to strengthen the tight type of the tester and reduce the difficulty of field wiring. 3.3. Bus configuration of the tester The hardware of the tester includes industrial PC built-in CP5611 communication card, two inverters and the bus coupler. Among these, industrial PC built-in CP5611 communication card is as master station and monitor station, two inverters are as the two slave stations respectively, the bus coupler is as a slave station. The terminal modules of the bus coupler are addressed uniformly by the master station. 4. The design of monitoring system base on Lab Windows/CVI The Lab Windows/CVI is a software development environment which is developed by the National Instruments firm. It provides for the familiar of the C language development workers to write test system, automatic test system, data collection system, process of prison system and other application of software [3], [4] . Configuration
Main interface Thread 1 Test rig monitoring
Monitoring interface Recording system Thread 2
Variable parameter setting Startup configuration parameters OPC configuration parameters Hydraulic system visualization Working state display Alarm prompt Running monitoring Variable monitoring Real-time curves Alarm record Historic records
Data processing
Data communication Fig. 3. The overall frame of tester monitoring system software
Pressure fuzzy PID control
According to the configuration of the field bus system, the monitoring software contains two functions are monitoring and control. These two functions are base on the data collection and use the multi-
1063 3
1064 4
Xiao Chun / Procedia Engineering (2011) 1061 – 1065 Xiao Chun ，etetal/al.Procedia Engineering 0015 (2011) 000–000
threading technology to coordinate data collection, data processing, interface operation to achieve a friendly man-machine interface, real-time better control effectively and more accurate monitoring software. The overall frame of the tester monitoring system software is shown in Fig 3. The monitoring software of the tester control system uses Lab Windows/CVI of NI. The DataSocket technology happens to be provided by NI and supports OPC technology agreements. So the system develops the OPC Client is base on the DataSocket technology to realize the communication between the upper machine, the spot I/O and the inverters. The graphics about the communication between OPC Client and OPC Server based on DataSocket technology is shown in Fig 4 [8], [9].
Call DS_Open, Create object and connection
Using configuration software OPC Server to join the bus network, and set a data item Start the OPC
Call the read
Call the write Release
Call DS_Open, Create object and connection
Stop the OPC
Release object
Fig. 4. Communication between OPC Client and OPC Serve that based on DataSocket technology
The tester control system software includes eight major interfaces. Such as programming configuration parameters, starting configuration, hydraulic diagram, pump valve control, variable control, operation monitoring, PID regulation and curves show. Each of the main interfaces has a number of sub-interfaces. The parameters configurations which include the run files, the I/O variables, PID regulation, curve display and the OPC Client parameters to complete the project system configuration [5]-[7]. The starting module mainly set some initial startup parameters of the injection pump. Including the total running time, steering, transmission ratio, start step number which initialize on the test files of the fuel pump. The main interface module displays the whole online system. It includes the operation on hydraulic system, tester’s running time, connection status on I/O modules, the operation state and other information. These can make the operators have a deep understanding for the situation of the tester. The curve muddle shows the real-time curve of the system variables and inquires the historical data and alarm messages. The history of the data and the alarm information are not stored in the database but to store by file form which in order to improve the real-time of system. The role of monitoring module is to monitor the test program of injection pump. Based on this module, the information of configuration and step which the tester is testing can be got by the operators. The role of fuzzy adaptive PID control is to control the pump outlet tube’s pressure of test bench. According to the working principle of test bench, both of the injection pump’s speed and expected value of oil outlet’s pressure are single-step changed, and the single-step running time is compared shorter. Thus, the oil outlet’s pressure should be controlled based on the new expectations at each step. For this reason, the regulation time of the control system should be short. Otherwise, the control of the current step may not be stable, and it also may be controlled in accordance with the parameters of the next step in the same time, which can’t meet the control requirements. The pump valve control module can choose the inlet channels, the system of heat exchanging, the start and stop of every pump controlled by the hydraulic system and the cooling system. Figure5 Communication between OPC Client and OPC Serve that based on DataSocket technology The main interface module function is display the whole system online. It includes the operation on hydraulic system, running time, the connection status on input/output module, the operation state and
Xiao Chun et al. // Procedia – 1065 Xiao Chun Procedia Engineering Engineering 15 00 (2011) (2011) 1061 000–000
other information. These can make the operators to have a deep understanding for the situation of the test bench. The curve module shows the real-time curve of the system variables and inquires the historical data and alarm messages. Considering requirement of real-time for the system, the history of the data and the alarm information are not stored in the database but to store by file form which in order to improve the real-time of system. The role of monitoring module is to monitor the test program of injection pump. Based on this module, the information of configuration and step which the test bench is testing can be got by the operator. The role of fuzzy adaptive PID control module is to control the pump outlet tube’s pressure of tester. According to the working principle of tester, both of the injection pump’s speed and expected value of oil outlet’s pressure are single-step changed, and the single-step running time is compared shorter. Thus, the oil outlet’s pressure should be controlled based on the new expectations at each step. For this reason, the regulation time of the control system should be short. Otherwise, the control of the current step may not be stable, and it also may be controlled in accordance with the parameters of the next step in the same time, which can’t meet the control requirements. The pump valve control module can choose the inlet channels, the system of heat exchanging, the start and stop of every pump controlled by the hydraulic system and the cooling system. 5. Conclusion In this paper, we have designed a monitoring system of the high pressure common rail injection pump durability tester with some advantages of low price, improving real-time performance, good intellectual performance, data concentration and simplicity of operation. At present, the monitoring system of the tester has been finished on the scene. Some features have been applied in the reality, and the results showed that the function and performance of the system had fulfilled the requirement. 6. References [1] Zhou Zhiming. Design and application of profibus bus system. China Electric Power Press;2009, p. 10–258. [2] Chen Jiyong, Guo Xijin, Li Shoujun. Research on master-slave communication that based on Profibus protocol. XuZhou: China mining university journal, 2008,23(4)； 243-251. [3] Zhang Yigang, Qiao Liyan. Virtual instrument software development environment: Lab windows/CVI6.0. Beijing: China Machine Press; 2002, p. 18-179. [4] Wang Jianxin, Yang Shifeng. Lab Windows/CVI test technology and project applications. Chemical industry press; 2006, p. 39-298. [5] Kim J H, Kim K C, Chong K P. Fuzzy pre-compensated PID controllers. IEEE Transactions on Control Systems Technology, 1995. 406～411. [6] Tao Yonghua. New PID control and its application. Machinery Industry Press; 2002, p. 101-106. [7] Niu Peifeng, Ren Juan, Wang Shuai. PID adaptive fuzzy control in the boiler main steam temperature control in the simulation study. Thermal power generation; 2007,37(6), p. 24-27. [8] Xiang Luan. The research and application of oil filed remote monitoring system that based on OPC technology. [Master's degree thesis]. Hubei: Huazhong university of science and technology; 2007. [9] Raúl Alves Santos, Julio E.Normey-Rico, Alejandro Merino Gómez. OPC based distributed real time simulation of complex continuous processes. Simulation Modelling Practice and Theory, 2005, 13(7): 525～547.
1065 5
