• 大型氦制冷机80 K预冷过程动态模拟及自动控制策略研究

    Dynamic Simulation and Automatic Control Study of the Precooling Process at 80 K for Large Helium Refrigerators

    • 在聚变堆主机关键系统综合研究设施(CRAFT)中,大型氦制冷机为超导磁体测试提供长期稳定的低温环境。论文针对CRAFT 中大型氦制冷机80 K预冷过程的复杂动态特性,基于软件EcosimPro及其低温库CRYOLIB,采用动态模拟仿真与分析相结合的方法开展了动态模拟,在模型中重构了四流股板翅式换热器,建立了80 K预冷回路的全流程模型。模拟仿真表明,冷箱系统存在巨大的热惯性,被控对象具有明显的长滞后特征、强非线性的气液相变特征,且在降温初期出现了高达5 K/min的过快降温速率和超过40 K的危险温差。为解决开环工况下出现的这些问题,设计了基于温差与降温速率双重约束控制回路和液氮分离器压力及液位控制回路。通过仿真验证表明,优化后的控制策略使得温差和降温速率均保持在安全阈值范围内,液氮分离器的压力和液位也符合预期,有效避免了大型大惯性低温装置的热冲击风险,增强了大型氦制冷机80 K预冷过程的可靠性。

       

      Abstract: In the Comprehensive Research Facility for Fusion Technology (CRAFT), a large-scale helium refrigeration system provides a long-term stable cryogenic environment for superconducting magnet testing. This paper investigates the complex dynamic characteristics of the 80 K precooling process of this system. Based on EcosimPro and its cryogenic library CRYOLIB, a combined approach of dynamic simulation and process analysis was adopted. In particular, a four-stream plate-fin heat exchanger was reconstructed in the model, and a full-process model of the 80 K precooling loop was established.Simulation results showed that the cold box system has very large thermal inertia. The controlled object exhibits a pronounced long time-delay response and strong nonlinearity associated with gas-liquid phase change. At the initial stage of cooldown, the model predicted an excessive temperature drop rate of up to 5 K/min and a hazardous temperature difference exceeding 40 K. These results indicate that, under open-loop operation, the process is exposed to substantial thermal-shock risk and cannot satisfy safe cooldown requirements.To address these issues, an optimized control strategy was developed. It includes a dual-constraint control loop based on both temperature difference and temperature drop rate, as well as pressure and liquid-level control loops for the liquid-nitrogen separator. The dual-constraint design is intended to simultaneously suppress local thermal gradients and limit the overall cooldown slope, while separator pressure and inventory are regulated to maintain stable operating conditions during transients.Further simulation-based validation showed that the optimized strategy keeps both the temperature difference and the temperature drop rate within predefined safety thresholds. Meanwhile, the pressure and liquid level of the liquid-nitrogen separator remain within expected operating ranges. Therefore, the proposed strategy effectively prevents thermal shock in this large-scale, high-inertia cryogenic system and significantly improves the reliability and operational safety of the 80 K precooling process in the CRAFT helium refrigeration system.

       

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