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Structural Principle of New Military Generator Set Controller

Oct. 29, 2018

With the rapid development of the electronics industry, a series of digital informational, intelligent and networked waves have been triggered, which have a major impact on the diesel generator or industry. A wide range of fully functional diesel generator sets have sprung up, notably the UK's DEEPSEA controller, Denmark's DELF and Germany's Koeman. These controllers have functions such as power collection, control of oil machine control parameters, various fault protection, LCD display, and two-way switching. However, these controllers collect and display various operating parameters of the generator and diesel engine, and detect whether these parameters are within the set range. If not, alarm or switch, the main parameters of the generator and diesel engine (such as the voltage generated by the generator and the speed of the diesel engine) can not be intervened, the adjustment ability is poor, and even there is almost no adjustment function.

Structural Principle of New Military Generator Set Controller.jpg


These parameters cannot be remotely adjusted and controlled if remote control is implemented. It is also difficult to meet military requirements in terms of function implementation, selection of electronic devices, low power consumption, environmental protection and energy saving, system expansion and anti-interference. According to the working environment and actual requirements of military products, the products introduce some new technologies and new ideas emerging from the rapid development of electronic technology into this design. For example, the United States apple popular in the global iphone capacitive touch screen technology and next-generation display technology (organic light-emitting display technology) OLED and other new technologies. In terms of concept, the modular design is implemented, the previous functional stacking design is abandoned, and the modules are connected by bus, so that users can define their own systems, making the system cost-effective, without wasting every penny of the user.


Hardware composition of a new military diesel generator set controller


The hardware of the controller adopts modular design, and the modules are connected by bus. Users can select their own module types and quantities according to actual needs, and define their own systems. The hardware of the controller is composed of a main control board, a power collection module, a diesel engine parameter acquisition module and a display module. This article takes two diesel generators as an example. If it is a diesel generator set, one power supply can save one oil machine parameter acquisition module.


Main Control Board


The main control board is based on the TMS320F2812 produced by Texas Instruments. The TMS320F2812 is the most advanced and powerful 32-bit fixed-point DSP chip in the world. It not only has digital signal processing capability, but also has powerful event management capability and embedded control function, especially suitable for measurement and control occasions with large-scale data processing. This controller selects s-class TMS320F2812, has a working temperature range of 40~+125°C, working frequency up to 150MHz, 8k×16-bit flash memory, 16-channel l2-bit ADC, 176-pin guarantee system is sufficient I/O port.


More importantly, there is a rich serial interface. The modular design of the controller is to connect each module with the main control board by various serial ports to realize the configurability and definability of the whole system, so that users can meet their own needs. It is convenient to combine and configure its own control system to make the user system more flexible, more cost-effective, and also able to achieve differentiated design, making the user's products more attractive.


In the design process of the power supply of the main control board, the concept of active power factor correction and energy saving and environmental protection was introduced. This control board meets the requirements of the latest and most demanding CEC and ENERGY STAR 2.0 standards and has a flexible power supply. It can be powered by AC or DC, or AC and DC. As long as either party has power, the controller can automatically switch, and AC power is preferred when AC is present. AC voltage input range AC85—265V. Select the phase voltage of any diesel generator set, rectify and perform active power factor correction, and use ON Semiconductor's NCP1653 active power factor calibration chip to make the control always work with AC factor close to 1 when using AC power supply. To avoid interference from other high-voltage equipment due to high-frequency interference generated by the rear-stage switching power supply.


The control chip of the switching power supply adopts the LNK616 of the American PI company LinkSwitch-II product series, which integrates a 700V power MOSFET oscillator, a novel on/off control state regulator, a self-biased high voltage switch current source, and a frequency. Jitter, current limit current sensed during each cycle, and thermal shutdown circuitry.


The main control board has a rich serial interface that supports flexible peripheral expansion and is the basis for modular design. In addition to the SPI and CAN that comes with the main control chip TMS320F2812, it also expands the RS232 and RS485 communication modes by using its universal synchronous/asynchronous transceiver (EUSART) module, using the SH of the TMS320F2812 and the CC2500 wireless transceiver manufactured by Texas Instruments. The chip expands zigbee communication, and realizes USB2.0 communication by using the parallel port of TMS320F2812 and the ISP1581 chip of Philips.


The digital potentiometer is used in the main controller to control the output voltage of the generator and the speed of the diesel engine, so that remote voltage regulation and frequency modulation become possible. If the two-machine uninterruptible power switching is realized remotely, it is easy to switch by simply adjusting the reactive and active components of one of the diesel generators and transferring the load to one of the genset.



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