基于扩展域的设计与半实物仿真方法及其在大型装备中的应用研究

Large equipment is composed of mechanical, electrical, hydraulic and control parts, its performance and operational status is mainly reflected in the comprehensive effect of multi-domains. Scale-up design of equipment involves the expansion process from mechanical domain to electrical, hydraulic and control domains. The comprehensive effect of multi-domains can be defined as extended domain. In the extreme environment, the extended domain would create the coupling of non-design-objectives which damage the whole function of equipment. Therefore, we establish a digital prototype of mechanical components and introduce the physical models of hydraulic system and electrical control into simulation loop. A semi-physical simulation system of large equipment can be established, and it could achieve early warning of singular evolution of large equipment. The project considers the air separation unit as carriers, and researches on the subjects of hybrid system, such as the formation and characteristics of the extended domain, extended domain coupling and solution in the digital prototype, the magnification of model and behavior in semi-physical simulation, and dynamic fusion of multi-dimensions between design and semi-physical simulation. Then, a prototype system of design and semi-physical simulation could be developed, and applied in the design of the super large air separation unit equipment.

大型装备由机械、电子、液压和控制部分组成，装备的性能和运行状态主要体现在多领域系统间的综合作用。装备的大型化设计是机械向电子、液压、控制等领域的扩展过程，当装备运行过程中处于某种服役环境时，多域间交互作用下的扩展域，产生非设计目标的耦合而破坏装备整体功能。因此，建立机械部件的数字样机，将液压和控制部分通过物理模型引入仿真回路，从而构成大型装备的半实物仿真系统，实现大型装备奇异演变的预警。本项目以空分成套装备为载体，研究混合系统中扩展域的形成机理与特性、扩展域在数字样机中的耦合与求解、半实物仿真中的模型与行为放大、集设计与半实物仿真的多维度动态融合。开发了装备设计与半实物仿真原型系统，并在超大型空分成套装备的设计中进行应用验证。

精馏塔和换热器为空分成套装备的主要部机，为了实现空分成套装备的放大设计，以精馏系统和板翅式换热器为研究对象，提出了物理-数学混合仿真方法。将半实物仿真概念引入精馏系统放大设计和板翅式换热器翅片性能测试的研究中。其中，将深低温精馏系统数学模型转化成仿真计算模型，实现精馏过程的数学仿真。构造填料塔的物理模型，并在物理模型基础上进行试验研究，通过系统环境中的相似关系，实现填料塔物理效应仿真，将填料塔物理效应模型引入精馏系统的仿真回路中。半实物仿真方法解决了现有空分成套装备只能进行物理仿真或数学仿真，难以实现整体系统级仿真的问题。同时，利用虚拟仪器技术开发了精馏系统物理-数学混合仿真平台和板翅式换热器翅片性能测试系统，实现12万等级内压缩流程的空分成套装备中精馏系统和低阻高效铝制板翅式换热器的开发。