R&D Outcomes

1、System integration design technology of diesel generator unit

Through years of technical accumulation and effective integration of interdisciplinary technologies, the company has a leading system integration design capability within the industry. With excellent system integration design technology, the company has developed competitive products in such areas as telecommunications and mains power system. In the field of nuclear power, for example, the nuclear island LOT80 system diesel generator unit for nuclear power plant is an independent backup power for nuclear power plant, and serves as an important security barrier for nuclear power plant. It requires high reliability performance for the control of execution system operation command in various links.

2、Product development and design technology

(1)Nuclear safety class power station development and design technology

The company’s nuclear safety class power station represents the high level of technological application in the diesel generator  industry. Because of extreme importance of service environment, its backup power has extremely high requirements for intelligence, controllability, reliability and safety. In accordance with EJ/T 625-2004 Criteria for Diesel-Generator Units Applied as Standby Power Supplies for Nuclear Power Generating Stations (equivalent to IEEE Std 387-1995IEEE Standard Criteria for Diesel-Generator Units Applied as Standby Power Supplies for Nuclear Power Generating Stations), the company uses simulation experiment, ageing analysis and shock test to design and verify the service performance of the nuclear island backup diesel generator  for nuclear power station, thus ensuring the quality and service life of products. The technological index of product reaches international advanced level. The invention patent declared by relevant development project, Nuclear Safety Class Diesel Generator Unit, has been authorized by National Intellectual Property Administration, and identified by Shanghai as hi-tech achievement transformation project and independent innovation product. Cooltech’s nuclear safety class power station, as 400V SBO power supply for 1000MW class APWR nuclear power unit, gives a big boost to China’s proprietary third-generation nuclear power product known as Hualong One, and proves to be technologically advanced across the world.

(2)Telecommunication base station power station design and design technology

Power integration technology is key to the development and design of diesel generator  for telecommunication base station. This technology integrates the backup power for base station and its relevant intelligent control system and fuel supply system into the sound-proof case and base to form a system. This system gathers digital, intelligent and networked technologies, and realizes such functions as manual/automatic start (shutdown), accurate measurement of data, alarm protection, “three remotes” and automatic switching  system(ATS). The product can operate continuously for hundreds of hours in an unmanned and remote base station.

The invention patent declared by relevant development project, Power Integration System for telecommunication Base Station, has been authorized by National Intellectual Property Administration, and identified by Shanghai as hi-tech achievement transformation project and independent innovation product.

(3)Vehicle-mounted power station system design technology

Vehicle-mounted power station is a mobile power supply, which is characterized in that the diesel generator  is integrated on the chassis of truck or trailer in the form of shelter. Its characteristics include quick movement, low noise operation, digital parallel operation, easy operation and all-weather work.

The overall design of the vehicle-mounted power station comprehensively considers such factors as refitting, vibration absorption, noise reduction, user-friendly operation and maintenance space, intelligent control and safety protection function, and integrates vehicle refitting technology, unit noise reduction technology, network communication technology and automatic control technology.

Traditional discrete component control system with simple functions is upgraded to hi-tech modular integrated control system. Various control functions are added, including unit protection, operation parameter display, historic record, intelligent monitoring and load optimization and management. It realizes control with less or no contact, improves operational reliability and achieves synchronous and parallel operation of up to 256 units.

With the characteristics of high mobility, high intelligence and easy operation, the vehicle-mounted power station has been widely used. This project, which has 7 proprietary patents and one computer software copyright, is recognized as hi-tech achievement transformation project in Shanghai. Its overall technological level enjoys leadership domestically and reaches the advanced level of similar products abroad.

3、Production process technology

(1)Mechanical assembly process technology for diesel generator unit

The company’s mechanical assembly process uses the flow step operation mode. The technical department follows the principle of quality, high efficiency, low consumption and safety in formulating operation process chart, standard operation procedure and process flow card for all series products. The working procedure of a certain quality control point is undertaken by a qualified operator. After each working procedure, the operator and inspector sign on the process flow card to ensure assembly quality and traceability. Power station products for telecommunication base station, which have uniform early working procedures, are produced with assembly line process to significantly improve production efficiency. The company’s fine mechanical assembly process effectively ensures the assembly quality and production efficiency of units, and enjoys a leading position within the domestic industry.

(2)Electrical assembly process technology for diesel generator unit

The company’s electrical assembly process uses the template operation mode. The technical department follows the principle of quality, high efficiency, low consumption and safety in formulating operation process chart, standard operation procedure and process flow card for all series products. Template for primary and secondary wiring of units is prepared in accordance with the requirements of drawing and the actual connection requirements of each model. After actual connection is confirmed to be correct, batch job is undertaken. This greatly improves assembly quality and production efficiency.

The company’s electrical assembly process enjoys a leading position in the domestic industry.

4、Testing and inspection technology

Testing and inspection capability is one of the key factors in determining a company’s competitiveness in the field of power station product application. Products used in mid-and high-end industries have higher technical requirements, and most of them need to be developed and designed according to specific requirements of customers. At the phase of prototype development, a series of tests are required to prove new products meet the design requirements. After prototype acceptance, all the products must be subject to various strict tests during volume production. After obtaining relevant inspection data, products can be delivered to the customers.

Presently, the company’s testing and inspection technology boasts a leading level in China. Through years of R&D and technological investment, the company has a domestically advanced diesel generator unit performance laboratory, which has passed the laboratory accreditation of China National Accreditation Service for Conformity Assessment (CNAS). This laboratory can test generator units in accordance with the relevant provisions of GB/T2820.5-2009 Reciprocating Internal Combustion Engine Driven Alternating Current Generating Sets. Part 5: Generating Sets, JB/T10303-2001 Technical Conditions of Power Frequency Diesel Generating Sets, GB/T2819-1995 General Specification for Mobile Electric Power Plant, YD/T502-2007 Diesel Generator Sets for Telecommunications and GJB 235A-1997 General Specification for Military Mobile Electric Power Plant.