Helicopter hydraulic pressurization oil tank test system and test method

Abstract

The invention belongs to the technical field of aircraft tests, and discloses a helicopter hydraulic pressurization oil tank test system and test method. The system comprises a comprehensive test bench and a tool bench. The tool table is used for fixing four tested hydraulic pressurizing oil tanks; the comprehensive test bench comprises a rack, and a hydraulic pump station, an electric control cabinet, a test operation station and a joint panel which are installed on the rack. The hydraulic pump station is connected with the joint panel and is used for providing a hydraulic oil source with pressure, temperature and flow required by the test; the electric control cabinet is connected with the connector panel, the test operation station and the hydraulic pump station, provides required power input, receives various instructions from the test operation station, collects test data of the comprehensive test bench, carries out calculation, and controls the hydraulic pump station to output a test state. The test operation station is used for controlling the hydraulic pump station and the electric control cabinet; the comprehensive test bench interacts hydraulic oil and communication control signals with the tool bench through the joint panel. The comprehensive test bench is also connected with the power cable through the joint panel.

Description

Technical Field

[0001] This invention belongs to the field of aircraft testing technology and discloses a test system and test method for a helicopter hydraulic booster tank. Background Technology

[0002] As a self-developed product of our institute, the hydraulic booster tank needs to undergo functional, performance, pressure, and durability tests according to the testing requirements during the tank's development process and the factory testing requirements after type approval. The hydraulic booster tank has been in production for many years, and the corresponding testing system was developed in 2001 and had been in use for 17 years prior to this invention. This system is nearing the end of its lifespan, experiencing frequent malfunctions and delaying testing progress. Furthermore, the original testing equipment could only test one tank at a time, and the control method was manual, resulting in low testing efficiency and failing to meet the testing requirements for batch production of the hydraulic booster tank.

[0003] With the increasing number of models using hydraulic booster tanks and the significant increase in the number of tanks delivered each year, the existing testing system can no longer meet the testing needs of batch production of hydraulic booster tanks. In order to improve the level of automation and testing efficiency, it is urgent to develop a new hydraulic booster tank testing system. Summary of the Invention

[0004] Objective: To provide a testing system and method for helicopter hydraulic booster tanks, used to complete functional tests, performance tests, pressure resistance tests, and durability tests of hydraulic booster tanks. The testing system can simultaneously handle the testing of four hydraulic booster tanks, improving testing efficiency.

[0005] Technical solution: This application provides a test system for helicopter hydraulic booster tanks, the system comprising: a comprehensive test bench and a tooling table; The tooling table is used to fix four hydraulic booster tanks for testing. The integrated test bench includes a frame and a hydraulic pump station, electrical control cabinet, test operation station, and connector panel mounted on the frame; The hydraulic pump station is connected to the connector panel to provide the hydraulic oil source with the required pressure, temperature and flow rate for the test; The electrical control cabinet is connected to the connector panel, test operation station and hydraulic pump station, providing the required power input, receiving various instructions from the test operation station, collecting test data from the integrated test bench and performing calculations, and controlling the hydraulic pump station to output the test status. Furthermore, the electrical control cabinet is the main part of the electrical control system, including the high-voltage control cabinet and the low-voltage control cabinet. It includes the power input, controller, relay group and other power distribution components required by the test system. The electrical components are provided with secondary isolation protection, and the PLC is the core of the control system.

[0006] The test operation station is used to control the hydraulic pump station and electrical control cabinet, and to complete the instruction input for all test items of the test system; Furthermore, the operator station panel is equipped with a 12-inch HMI high-definition touch screen and switches, buttons, valve adjustment handles, indicator lights, pressure and temperature digital displays, which facilitates the monitoring and operation of the test system.

[0007] The integrated test bench interacts with the tooling table via a connector panel to exchange hydraulic oil and communication control signals; The integrated test bench is also connected to the power cable via a connector panel.

[0008] Furthermore, the tooling table includes: The test bench serves as a platform support; Eight clamp sliding guide rails are fixed in pairs on the test hydraulic booster tank mounting plate; A set of test hydraulic booster tank fixing brackets are installed on two adjacent clamp sliding guide rails, and a test hydraulic booster tank is fixed together by a set of test hydraulic booster tank fixing brackets; The clamp guide rail locking device is used to fix the test hydraulic booster tank fixing frame; A micro switch sliding rail is installed at each of the four corner edges of the upper surface of the test bench, parallel to the clamp sliding rail; Two microswitches are installed on each microswitch sliding rail, and two microswitch rail locking devices are used to lock the two microswitches respectively; The hydraulic oil tank quick-connect coupling panel includes an oil storage chamber oil circuit interface, a pressure boosting chamber oil circuit interface, a return oil interface, and a control signal interface.

[0009] Furthermore, the tooling also includes: a control valve assembly, comprising a flow regulating valve, a first solenoid valve, a second solenoid valve, a proportional relief valve, a first reversing solenoid valve, a first pressure sensor, and a second pressure sensor; The inlet of the flow regulating valve is connected to the oil circuit interface of the oil storage chamber on the quick-change connector panel of the hydraulic oil tank, the outlet of the flow regulating valve is connected in series with the first solenoid valve, and the outlet of the first solenoid valve is connected to the first pressure sensor. The second solenoid valve is connected in parallel with the proportional relief valve. Its inlet is connected to the outlet of the first solenoid valve, and its outlet is connected to the return oil interface of the quick-change connector panel of the oil circuit of the pressure tank. The third solenoid valve interface 1 is connected to the hydraulic oil tank quick-change connector panel pressurization chamber oil circuit interface, the third solenoid valve interface 2 is connected to the hydraulic oil tank quick-change connector panel return oil interface, and the third solenoid valve interface 3 is connected in series with the second pressure sensor.

[0010] Furthermore, the tooling also includes a waste oil collection tank for collecting waste oil during testing.

[0011] Furthermore, the hydraulic pump station includes a hydraulic oil tank assembly, an oil storage chamber motor pump unit, a booster chamber motor pump unit, a pump control valve assembly, and hydraulic pipelines, providing a hydraulic oil source for the test.

[0012] Furthermore, the hydraulic oil tank assembly includes: an oil tank, a temperature sensor, a level gauge, an air filter, a suction filter, a return filter, and a radiator. It provides a stable oil supply for the test system and ensures the stable and efficient operation of the system through various means such as heat dissipation, air bubble separation, and impurity precipitation, thereby improving the overall performance of the system.

[0013] Temperature sensor 92, level gauge 93, and air filter 94 are installed on the oil tank. Suction filter 95 is installed on the hydraulic line at the oil tank outlet and connected to the pump. Return filter 96 is connected in series with radiator 97 and installed on the hydraulic line at the oil tank inlet.

[0014] Furthermore, when the temperature value reported by the temperature sensor rises to 50°C, the heat sink starts to work and dissipate heat.

[0015] Furthermore, the oil storage chamber motor pump unit contains two sets of parallel motor pump units, one of which serves as a redundant backup to provide oil source for the oil storage chamber of the test hydraulic booster tank; the booster chamber motor pump unit contains two sets of parallel motor pump units, one of which serves as a redundant backup to provide oil source for the booster chamber of the test hydraulic booster tank.

[0016] Furthermore, the pump control valve assembly includes a check valve, a first hydraulic filter, a direct-acting relief valve, a manual shut-off valve, a pilot relief valve, a directional solenoid valve, and a second hydraulic filter, which control the flow rate, pressure, and direction of the hydraulic oil source.

[0017] The outlet of the one-way valve is connected to the first pressure oil filter; The outlet of the check valve is connected to the inlet of the direct-acting relief valve and the inlet of the manual shut-off valve. The pilot relief valve is connected in parallel with the reversing solenoid valve, the inlet is connected to the second pressure oil filter, and the outlet is connected to the outlet of the direct-acting relief valve.

[0018] A test method for helicopter hydraulic booster tanks is provided. The method involves using a comprehensive test bench and a tooling table to perform functional, performance, and durability tests on four tanks. The four tanks are installed on the tooling table, and the hydraulic pipeline system and control system are connected through hydraulic hoses and electrical cables. The oil ports A1 and B of the test tank are open, while the oil port A2 is closed. The required test items are selected through the operator station.

[0019] The integrated test bench hydraulic station is equipped with two power units (namely, the oil storage chamber power unit and the booster chamber power unit). Each power unit contains two sets of motor pump sets, one of which serves as a redundancy backup. The oil storage chamber pump set has a power of 3kW, a speed of 1440rpm, and a flow rate of approximately 70L / min. It can simultaneously supply oil to four oil storage chambers, meeting the requirement of supplying 8L of oil to each oil storage chamber within 30s. The booster chamber pump set has a power of 4kW, a speed of 1440rpm, and a flow rate of approximately 20L / min. It can simultaneously supply oil to four booster chambers, meeting the requirement of supplying 2.5L of oil to each booster chamber within 30s. It can simultaneously control four large oil tanks at a reversing frequency of 1 time / min.

[0020] For oil reservoir pressure control: The test hydraulic booster tank oil reservoir pressure is 0.25MPa±0.05MPa. This reservoir pressure is relatively low, and even small changes in flow rate have a significant impact on pressure. Therefore, each oil reservoir circuit is equipped with an independently controlled throttle valve and proportional relief valve. The oil reservoir is supplied by the main pump of the oil reservoir pump group. When the direct-acting relief valve is energized, it provides 1MPa pressure to the system. The proportional relief valve (pressure range 0-2.07MPa) is set to 0.25MPa. When the oil reservoir needs to be supplied, the solenoid valve is energized, and the flow rate is adjusted to the required test flow rate through the throttle valve. When there are flow fluctuations, the proportional relief valve automatically adjusts to eliminate pressure changes caused by flow rate variations. Simultaneously, a manual shut-off valve is installed in the oil reservoir circuit to fine-tune the system pressure, thereby ensuring that the oil reservoir pressure is 0.25MPa±0.05MPa.

[0021] For pressure control of the booster chambers: The 10MPa requirement for the four booster chambers is controlled by the overflow valve of the main pump of the booster chamber pump set. The booster chambers are supplied with oil by the main pump of the booster chamber pump set. The pilot overflow valve (pressure range of 0.4-35MPa) is set to 10MPa, and the main pump continuously provides 10MPa pressure to the system.

[0022] The control valve group in the tooling unit controls the reversing of the test oil tanks. The extension and retraction of the oil tank piston rod triggers a microswitch as a reversing or stop signal: when oil enters the reservoir and returns to the pressurization chamber, the oil tank piston rod extends. When the piston rod triggers the microswitch, a pre-programmed reversing procedure (delayed reversing or immediate reversing) is initiated. At this time, oil enters the pressurization chamber and returns to the reservoir, and the oil tank piston rod retracts. After the four oil tank control valves operate synchronously, the four oil tanks reach their reversing positions at different times. Therefore, when each oil tank reaches its designated position and triggers the microswitch, the reservoir and pressurization chambers each have separate control valves to control the oil circuit opening and closing, ensuring that the reversing of the four oil tanks is independent and unaffected by asynchrony.

[0023] Thermal balance: When the temperature value fed back by the oil tank temperature sensor of the integrated test bench rises to 50℃, the radiator starts to work to dissipate heat.

[0024] The specific experimental procedure is as follows: The sealing test procedure is as follows: Step 1: Fixing and connecting the four hydraulic booster tanks under test; Step 2: Select the test item through the test operation station: sealing test; Step 3: Enter the sealing test interface and set the required test parameters; Step 4: Start the oil storage chamber motor pump set and the booster chamber motor pump set; Step 5: Adjust the system pressure to the required test pressure using a direct-acting relief valve, manual shut-off valve, flow regulating valve, proportional relief valve, and pilot-operated relief valve; Step Six: Start the test control program of the test operation station to complete the test. The first and second solenoid valves are energized at the same time, the third solenoid valve is de-energized, and the piston rod of the hydraulic booster tank under test extends. Step 7: After the piston rod of the hydraulic booster tank under test has fully extended, adjust the manual shut-off valve clockwise and observe the value shown by the first pressure sensor. When the value reaches 0.25MPa±0.05MPa, stop adjusting the manual shut-off valve and observe for 3 minutes. Step 8: After observing for 3 minutes, check the hydraulic booster tank of the test subject for leaks; Step 9: The first and second solenoid valves are simultaneously de-energized, the third solenoid valve is energized, and the piston rod of the hydraulic booster tank under test retracts. Step 10: After the piston rod of the hydraulic booster tank under test has fully retracted into place, observe the value shown by the second pressure sensor, adjust the pilot relief valve handle to the value shown as 10MPa, stop adjusting when the value reaches 10MPa, and observe for 3 minutes. Step 11: After observing for 3 minutes, check the hydraulic booster tank of the test subject for leaks.

[0025] The pressurization test process is as follows: Step 1: Fixing and connecting the four hydraulic booster tanks under test; Step 2: Select the test item through the test operation station: pressurization pressure test; Step 3: Enter the pressure boosting test interface and set the required test parameters; Step 4: Start the oil storage chamber motor pump set and the booster chamber motor pump set; Step 5: Adjust the system pressure to the required test pressure using a direct-acting relief valve, manual shut-off valve, flow regulating valve, proportional relief valve, and pilot-operated relief valve; Step Six: Start the test control program of the test operation station to complete the test. The first and second solenoid valves are energized at the same time, the third solenoid valve is de-energized, and the piston rod of the hydraulic booster tank under test extends until it is fully extended. Step 7: The first and second solenoid valves are simultaneously de-energized, the third solenoid valve is energized, and the piston rod of the hydraulic booster tank under test retracts. Step 8: Observe the value shown by the second pressure sensor and adjust the pilot relief valve handle to the value shown as 10MPa; Step 9: After the hydraulic tank retracts a section (3-5 seconds), energize the second solenoid directional valve. At this time, the hydraulic tank should remain stationary. Observe whether the value shown by the first pressure sensor is 0.25MPa±0.05MPa. Step 10: De-energize the second solenoid directional valve, repeat step 9 twice, and check the results.

[0026] The durability test process is as follows: Step 1: Fixing and connecting the four hydraulic booster tanks under test; Step 2: Select the test item through the test operation station: durability test; Step 3: Enter the durability test interface and set the required test parameters; Step 4: Start the oil storage chamber motor pump set and the booster chamber motor pump set; Step 5: Adjust the system pressure to the required test pressure using a direct-acting relief valve, manual shut-off valve, flow regulating valve, proportional relief valve, and pilot-operated relief valve; Step Six: Start the test control program on the test operation station to complete the test; Step 7: When the first and second solenoid valves are energized simultaneously and the third solenoid valve is de-energized, the oil inlet chamber of the hydraulic booster tank under test enters the booster chamber and the oil outlet chamber returns oil, and the piston rod of the tank extends; when the piston rod triggers the micro switch, the reversal is controlled by the set program. Step 8: The first and second solenoid valves are simultaneously de-energized, while the third solenoid valve is energized. Oil returns from the reservoir chamber of the hydraulic booster tank to the booster chamber, causing the tank piston rod to retract. When the piston rod triggers the microswitch, the program controls the reversal, returning to Step 7. Step Nine: The test control program automatically repeats Steps Seven and Eight until the set number of cycles is reached.

[0027] In summary, the beneficial effects of the present invention are as follows: With the increasing use of hydraulic booster tanks in various models, the number of tanks delivered annually has increased significantly, leading to exceptionally heavy testing workloads. Previously, this invention could only complete the testing of one tank at a time. When conducting durability tests (12,000 cycles) on hydraulic booster tanks, only 300 tests could be completed per day, and completing just 12,000 durability tests would take approximately two months (excluding holidays). This invention, with a PLC as the core of the control system, significantly improves automation and can simultaneously handle functional, performance, and durability tests on four tanks. Each test saves more than three-quarters of the testing time, greatly improving testing efficiency, shortening the testing cycle, and reducing testing costs, thus meeting the testing requirements for batch production of hydraulic booster tanks. Attached Figure Description

[0028] Figure 1 Block diagram of the test system; Figure 2 Internal structure diagram of the integrated test bench; Figure 3 External schematic diagram of the integrated test bench; Figure 4 Tooling table structure diagram; Figure 5 Front view of the tooling table; Figure 6 Hydraulic schematic diagram of the test system; Explanation of markings in the diagram: - Quick-connect couplings for hydraulic lines; Hydraulic hose with quick-change coupling; Control / signal cable with aviation connector; 1-Comprehensive test bench; 2-Tooling table; 3-Hydraulic piping system; 4-Electrical control system; 5-Hydraulic hose with quick-connect coupling; 6-Control / signal cable with aviation plug; 7-Power cable with industrial plug; 8-Comprehensive test bench frame; 9-Oil tank assembly; 10-Oil storage chamber motor pump unit; 11-Boosting chamber motor pump unit; 12-Pump control valve assembly; 13-Electrical control cabinet; 14-Operator station; 15-Main oil circuit quick-connect coupling panel; 16-Aerospace plug panel; 17-Industrial plug panel; 18-Tooling table frame; 19-Test hydraulic boosting oil tank mounting bracket; 20-Clamp sliding guide rail; 21-Clamp guide rail locking device; 22-Micro switch sliding guide rail; 23-Micro switch guide rail locking device; 24-Control valve assembly; 25-Oil collection tank; 26-Hydraulic oil tank oil circuit quick-connect coupling panel; 91-Oil tank; 92-Temperature sensor, 93-Level gauge, 94-Air filter, 95-Suction oil filter, 96-Return oil filter, 97-Radiator; 121-Check valve, 122-Direct-acting relief valve, 123-Manual shut-off valve, 124-Pilot relief valve, 125-Reversing solenoid valve, 126-Pressure oil filter; 241-Flow regulating valve, 242, 243, 247-Solenoid valve, 244-Proportional relief valve, 245, 246-Pressure sensor. Detailed Implementation

[0029] A test system for a helicopter hydraulic booster tank, such as Figure 1 As shown, the test system includes: a comprehensive test bench 1, a tooling table 2, a hydraulic piping system 3, an electrical control system 4, hydraulic hoses with quick-connect couplings 5, control / signal cables with aviation plugs 6, and power cables with industrial plugs 7. Among these, the oil tank assembly 9, the oil reservoir motor pump assembly 10, the booster chamber motor pump assembly 11, and the pump control valve assembly 12 of the hydraulic piping system 3 are installed in the comprehensive test bench 1, as shown... Figure 2 As shown, this is a path for supplying and discharging hydraulic oil to the test system, and for providing the flow rate and pressure of the oil required for the test; the control valve assembly 24 in the hydraulic pipeline system 3 is installed in the tooling table 2, as shown. Figure 3As shown, the hydraulic booster tank and reservoir oil source in the test system are used to control the flow rate, pressure, and piston rod movement reversal. The hydraulic pipeline system between the integrated test bench 1 and the tooling table 2 is connected by hydraulic hoses 5 and quick-connect couplings 15 on the main oil circuit, realizing the delivery and discharge of oil source between the integrated test bench and the tooling table. The interface of the hydraulic booster tank is a 24° non-flared connector (HB5970-86), and the interface of other pipeline connectors adopts the 74° flared connection (HB4-1-83). The electrical control system 4 consists of the controlled objects (pumps, valves, signal sensors, micro switches / limit switches), the electrical control cabinet 13, and the operator station 14. The electrical control cabinet 13 and the operator station 14 are installed in the integrated test bench. In test bench 1, the controlled objects are located on the integrated test bench and the tooling table respectively; the PLC is the core of the control system. It receives various instructions from the operator station 14, collects data from various signal sensors of the test bench and performs calculations, drives the controlled objects and outputs the test status to achieve the purpose of testing and monitoring; the controlled objects of the tooling table 2 are connected to the integrated test bench through the aviation plug panel via the control / signal cable 6, realizing the control and data acquisition of the controlled objects (valve, signal sensor, micro / limit switch) in the tooling table by the electrical control system 4; the external power supply is connected from the industrial plug through the power cable 7 to provide power to the test system; both the integrated test bench and the tooling table are equipped with rollers and push handles, which can be moved flexibly as needed.

[0030] like Figure 2 The integrated test bench 1 includes an integrated test bench frame 8, an oil tank assembly 9, an oil storage chamber motor pump unit 10, a booster chamber motor pump unit 11, a pump control valve assembly 12, an electrical control cabinet 13, an operating station 14, a main oil circuit quick-connect connector panel 15, an aviation plug panel 16, and an industrial plug panel 17. The integrated test bench frame 8 provides an installation platform for all accessories within the integrated test bench, and is equipped with casters and handles to facilitate movement of the integrated test bench; such as... Figure 4 The oil tank assembly 9 includes an oil tank 91, a temperature sensor 92, a level gauge 93, an air filter 94, a suction filter 95, a return filter 96, and a radiator 97. The temperature sensor 92, the level gauge 93, and the air filter 94 are installed on the oil tank. The suction filter 95 is installed on the hydraulic line at the oil tank outlet and connected to the pump. The return filter 96 is connected in series with the radiator 97 and installed on the hydraulic line at the oil tank outlet.

[0031] To provide a stable oil supply to the test system, various methods such as heat dissipation, air bubble separation, and impurity sedimentation are used to ensure the stable and efficient operation of the system, thereby improving the overall performance of the system. The oil storage chamber motor pump unit 10 contains two sets of motor pumps, one of which serves as a redundant backup, providing oil to the oil storage chamber of the tested hydraulic booster tank. The booster chamber motor pump unit 11 contains two sets of motor pumps, one of which serves as a redundant backup, providing oil to the booster chamber of the tested hydraulic booster tank. Figure 4The pump control valve assembly 12 includes a check valve 121, a direct-acting relief valve 122, a manual shut-off valve 123, a pilot relief valve 124, a directional solenoid valve 125, and a hydraulic oil filter 126. The outlet of the check valve 121.1 (121.2) is connected to the hydraulic oil filter 126.1; the outlet of the check valve 121.1 (121.2) is connected to the inlet of the direct-acting relief valve 122 and the inlet of the manual shut-off valve 123; the pilot relief valve 124 is connected in parallel with the directional solenoid valve 125, with its inlet connected to 126.2 and its outlet connected to the outlet of the direct-acting relief valve 122, thereby controlling the flow rate, pressure, and direction of the hydraulic oil source. Electrical control cabinet 13 is the main part of electrical control system 4, including high-voltage control cabinet and low-voltage control cabinet. It includes the power input, controller, relay group and other power distribution components required by the test system. The electrical components are provided with secondary isolation protection. PLC is the core of the control system. It receives various instructions from operator station 14, collects data from various signal sensors of the test bench and performs calculations, drives the controlled object and outputs the test status to achieve the purpose of testing and monitoring. The operator station 14 panel is equipped with a 12-inch HMI high-definition touch screen and switches, buttons, valve adjustment handles, indicator lights, pressure and temperature digital displays. To facilitate the monitoring and operation of the testing system, users can input commands for all test items through the operation station 14 and monitor the test status through the panel and indicator lights; the hydraulic quick-change connector panel 15 is connected to the tooling table through the hydraulic hose 5 to realize the delivery and discharge of oil source between the integrated test bench and the tooling table; the aviation plug panel 16 is connected to the tooling table through the control / signal cable 6 to realize the control of the controlled objects in the tooling table and data acquisition by the electrical control system; the industrial plug panel 17 is connected to an external AC380V power supply through the power cable 7 to provide power to the testing system.

[0032] like Figure 3The fixture 3 includes a fixture frame 18, a test hydraulic booster tank mounting bracket 19, a clamp sliding guide rail 20, a clamp guide rail locking device 21, a micro switch sliding guide rail 22, a micro switch guide rail locking device 23, a control valve group 24, an oil collection tank 25, a hydraulic oil tank quick-connect coupling panel 26, a main oil circuit quick-connect coupling panel 15, and an aviation plug panel 16. It can simultaneously mount four hydraulic booster tanks for testing. The fixture frame 18 provides an installation platform for all accessories in the fixture, and is equipped with rollers and push handles for easy movement of the fixture. The test hydraulic booster oil... The tank mounting bracket 19 uses pull-tab type clamps with oil-resistant rubber glued inside to reduce wear on the tank surface and facilitate quick fixation of the tested hydraulic booster tank. Two pull-tab type clamps are respectively mounted on clamp sliding guide rails 20, which have locking devices 21 for easy switching and fixing of the large and small tanks. Two microswitches are respectively mounted on microswitch sliding guide rails 22, which have locking devices 23 for easy fixing of the microswitches when switching between large and small tanks. The microswitches provide reversing signals for the extension and retraction of the piston rod during the test of the tested hydraulic booster tank. Figure 4The control valve assembly 24 includes a flow regulating valve 241, a solenoid directional valve 242, a solenoid directional valve 243, a proportional relief valve 244, a pressure sensor 245, a pressure sensor 246, and a solenoid directional valve 247. The inlet of the flow regulating valve 241.1 (241.2 / 241.3 / 241.4) is connected to the oil circuit interface of the oil reservoir panel of the oil circuit quick-connect connector of the pressure oil tank. The outlet of the flow regulating valve 241.1 (241.2 / 241.3 / 241.4) is connected in series with the solenoid directional valve 242.1 (242.2 / 242.3 / 242.4). The outlet of the solenoid directional valve 242.1 (242.2 / 242.3 / 242.4) is connected to the pressure sensor 245.1 (245.2 / 245.3 / 245.4); the solenoid directional valve 243.1 (243.2 / 243.3 / 243.4) and the proportional relief valve 244.1 (244.2 / 244.3 / 244.4) are connected in parallel, with the inlet connected to the outlet of the solenoid directional valve 242.1 (242.2 / 242.3 / 242.4) and the outlet connected to the return oil interface T port of the quick-change connector panel of the oil pressure tank. The electromagnetic directional valve 247 interface 1 is connected to the hydraulic oil tank quick-change connector panel's booster chamber oil circuit interface P2 port; the electromagnetic directional valve 247 interface 2 is connected to the hydraulic oil tank quick-change connector panel's return oil interface T port; and the electromagnetic directional valve 247 interface 3 is connected in series with the pressure sensor 246 to realize the flow rate, pressure, and piston rod movement reversing control of the hydraulic booster tank under test. The oil collection tank 25 is used to collect waste oil during the test for recycling. The main oil circuit quick-change connector panel 15 is connected to the integrated test bench via hydraulic hose 5, providing a connection between the tooling table and the integrated test bench. The oil source transportation and discharge path; the hydraulic oil tank quick-change connector panel 26 is connected to the test hydraulic booster oil tank through the hydraulic hose 5, providing the oil source transportation and discharge path between the tooling table and the test hydraulic booster oil tank; the test hydraulic booster oil tank interface is a 24° non-flared connector (HB5970-86), and other pipeline connection interfaces adopt the aviation standard 74° flared connection form (HB4-1-83); the aviation plug panel 16 is connected to the integrated test bench through the control / signal cable 6, realizing the control of the test status of the test hydraulic booster oil tank by the electrical control system 4.

[0033] A test method for helicopter hydraulic pressurization tanks involves conducting sealing tests, pressurization pressure tests, and durability tests on four tanks using a comprehensive test bench 1 and a tooling table 2 at room temperature. The four tanks are then arranged according to... Figure 3 Installed on the tooling table, the hydraulic piping system and electrical control system are connected via hydraulic hose 5 and electrical cables 6 and 7; for example... Figure 4 The oil tank A1 and B ports are open, while the oil tank A2 port is closed; the required test items are selected through the operation station 14 for testing.

[0034] like Figure 4The test system has two power units (the oil reservoir power unit and the booster chamber power unit). Each power unit includes two sets of motor-pump sets (oil reservoir pump set 10 and booster chamber pump set 11), with one set serving as a redundancy backup. Oil reservoir pump set 10 has a power of 3kW, using a Y110L2-4 motor with a speed of 1440rpm. Booster chamber pump set 11 has a power of 4kW, using a Y112M-4 motor with a speed of 1440rpm. To ensure the reciprocating operation time of the tested hydraulic booster tank, the main pump of pump set 10 has a displacement of 50ml / r and a flow rate of approximately 70L / min, capable of simultaneously supplying oil to four oil reservoirs, meeting the requirement of supplying 8L of oil to each reservoir within 30 seconds. The main pump of pump set 11 has a displacement of 13.9ml / r and a flow rate of approximately 20L / min, capable of simultaneously supplying oil to four booster chambers, meeting the requirement of supplying 3L of oil to each booster chamber within 30 seconds. Therefore, it satisfies the requirement to control four large oil tanks simultaneously at a commutation frequency of 1 time / min.

[0035] The pressure in the oil storage chamber is 0.25MPa±0.05MPa. Since the pressure in this chamber is relatively low, even a small change in flow rate will have a significant impact on the pressure change. Therefore, each oil storage chamber is equipped with an independently controlled throttle valve 241 and a proportional relief valve 244. The 10MPa requirement for the four booster chambers is controlled by the relief valve 124.

[0036] For oil reservoir pressure control: the oil reservoir is supplied with oil by the main pump 10. When the solenoid relief valve 122 is energized, it provides a pressure of 1MPa to the system. The proportional relief valve 244 (pressure range of 0-2.07MPa) is set to 0.25MPa. When the oil reservoir needs to be supplied with oil, the solenoid valve 242 is energized, and the flow rate through the throttle valve 241 is about 16L. When there is a flow fluctuation, the proportional relief valve 244 automatically adjusts to eliminate the pressure change caused by the flow change. At the same time, a manual shut-off valve 123 is set in the oil circuit of the oil reservoir to adjust the pressure according to the pressure value fed back by the pressure sensor 245, so as to ensure that the oil reservoir pressure is 0.25MPa±0.05MPa.

[0037] For pressure control of the booster chamber: the booster chamber is supplied with oil by the main pump 11, and the pilot relief valve 124 (pressure range of 0.4-35MPa) is set to 10MPa. When the booster chamber needs to be supplied with oil, the solenoid valve 247 is energized. The relief valve 124 is equipped with a manual pressure adjustment handle to adjust the pressure according to the pressure value fed back by the pressure sensor 246, so as to ensure that the pressure of the booster chamber is 10MPa.

[0038] Reversing control: Control valve assembly 24 is mounted on a tooling table. The extension and retraction of the oil tank piston rod triggers a microswitch as a reversing or stop signal. When oil enters the reservoir and returns to the pressurization chamber, after the piston rod triggers the microswitch, the reversing is controlled by a set program (delayed reversing or immediate reversing). At this time, oil enters the pressurization chamber and returns to the reservoir. Solenoid valve 247 is energized, while solenoid valves 242.1 (242.2 / 242.3 / 242.4) and 243.1 (243.2 / 243.3 / 243.4) are de-energized, and the oil tank piston rod retracts.

[0039] After the four oil tank control valves act synchronously, the four oil tanks reach the reversing position at different times. Therefore, when each oil tank reaches the designated position and triggers the micro switch, the oil storage chamber and the booster chamber of the oil tank have separate control valves (solenoid valves 242, 243 and proportional relief valve 244) to control the oil circuit opening and closing, so that the reversing of the four oil tanks is independent and not affected by the asynchrony.

[0040] Thermal balance: When the temperature value fed back by the oil tank temperature sensor 92 of the integrated test bench rises to 50℃, the radiator 97 starts to work to dissipate heat.

[0041] Example 1: The sealing test process is as follows: Select the sealing test item through the operation station 14 and enter the sealing test interface to set the required test parameters; start the oil storage chamber pump group 10 and the booster chamber pump group 11; adjust the system pressure to the required test pressure through the direct-acting relief valve 122, manual shut-off valve 123, flow regulating valve 241.1 (241.2 / 241.3 / 241.4), proportional relief valve 244.1 (244.2 / 244.3 / 244.4), and pilot relief valve 124; start the test control program of the test operation station to complete the test. Solenoid valves 242.1 (242.2 / 242.3 / 242.4) and 243.1 (243.2 / 243.3 / 243.4) are energized simultaneously, solenoid valve 247 is de-energized, and the oil tank piston rod extends; after the piston rod of the hydraulic booster oil tank under test is fully extended, adjust the manual shut-off valve clockwise. 123. Observe the value shown by pressure sensor 245.1 (245.2 / 245.3 / 245.4). When the value reaches 0.25MPa±0.05MPa, stop adjusting manual shut-off valve 123 and observe for 3 minutes. After 3 minutes, check whether there is any leakage in the tested hydraulic booster tank. Solenoid valves 242.1 (242.2 / 242.3 / 242.4) and 243.1 (243.2 / 243.3 / 243.4) are simultaneously de-energized, solenoid valve 247 is energized, and the tank piston rod retracts. After the piston rod of the tested hydraulic booster tank has fully retracted, observe the value shown by pressure sensor 246. Adjust the handle of pilot relief valve 124 to a value of 10MPa. When the value reaches 10MPa, stop adjusting and observe for 3 minutes. After 3 minutes, check whether there is any leakage in the tested hydraulic booster tank.

[0042] Example 2: The pressurization test process is as follows: Select the booster pressure test item through the operation station 14, and enter the booster pressure test interface to set the required test parameters; start the oil reservoir pump group 10 and the booster pump group 11; adjust the system pressure to the required test pressure through the direct-acting relief valve 122, manual shut-off valve 123, flow regulating valve 241.1 (241.2 / 241.3 / 241.4), proportional relief valve 244.1 (244.2 / 244.3 / 244.4), and pilot relief valve 124; start the test control program of the test operation station to complete the test, and simultaneously obtain the required test pressure through solenoid valves 242.1 (242.2 / 242.3 / 242.4) and 243.1 (243.2 / 243.3 / 243.4). When the hydraulic tank is de-energized, solenoid valve 247 is de-energized, and the oil tank piston rod extends until it is fully extended. Simultaneously, solenoid valves 242.1 (242.2 / 242.3 / 242.4) and 243.1 (243.2 / 243.3 / 243.4) are de-energized, solenoid valve 247 is energized, and the oil tank piston rod retracts. Observe the value shown by pressure sensor 246, and adjust the pilot relief valve 124 handle until its value is 10 MPa. After the hydraulic tank retracts a certain distance (3-5 seconds), energize solenoid valve 243.1 (243.2 / 243.3 / 243.4). At this time, the hydraulic tank should remain stationary. Observe whether the value shown by pressure sensor 245.1 (245.2 / 245.3 / 245.4) is 0. 25MPa±0.05MPa; When solenoid valves 243.1 (243.2 / 243.3 / 243.4) are de-energized, the piston rod of the oil tank retracts. After the hydraulic oil tank retracts a certain distance (3-5 seconds), energize solenoid valves 243.1 (243.2 / 243.3 / 243.4). At this time, the hydraulic oil tank should remain stationary. Observe whether the value shown by pressure sensor 245.1 (245.2 / 245.3 / 245.4) is 02.5MPa±0.05MPa. Repeat twice and check the result.

[0043] Example 3: The durability test process is as follows: Select the durability test item through operating station 14, enter the durability test interface to set the required test parameters; start the oil reservoir pump group 10.1 (10.2) and the booster pump group 11.1 (11.2); adjust the system pressure to the required test pressure through direct-acting relief valve 122, manual shut-off valve 123, flow regulating valve 241.1 (241.2 / 241.3 / 241.4), proportional relief valve 244.1 (244.2 / 244.3 / 244.4), and pilot relief valve 124; start the test control program of the test operating station to complete the test, and use solenoid valve 242.1 (242.2 / 242.3 / 242.4) and solenoid valve 2 When 43.1 (243.2 / 243.3 / 243.4) is energized, solenoid valve 247 is de-energized, oil enters the reservoir chamber of the tested hydraulic booster tank and returns to the booster chamber, causing the tank piston rod to extend. When the piston rod triggers a microswitch, the reversal is controlled by a set program. When solenoid valves 242.1 (242.2 / 242.3 / 242.4) and 243.1 (243.2 / 243.3 / 243.4) are de-energized, solenoid valve 247 is energized, oil returns to the reservoir chamber of the tested hydraulic booster tank and enters the booster chamber, causing the tank piston rod to retract. When the piston rod triggers a microswitch, the reversal is controlled by a set program. The test control program automatically repeats the extension and retraction steps until the set number of cycles is reached.

Claims

1. A test system for a helicopter hydraulic booster tank, characterized in that, The system includes: a comprehensive test bench and a tooling table; The tooling table is used to fix four hydraulic booster tanks for testing. The integrated test bench includes a frame and a hydraulic pump station, electrical control cabinet, test operation station, and connector panel mounted on the frame; The hydraulic pump station is connected to the connector panel to provide the hydraulic oil source with the required pressure, temperature and flow rate for the test; The electrical control cabinet is connected to the connector panel, test operation station and hydraulic pump station, providing the required power input, receiving various instructions from the test operation station, collecting test data from the integrated test bench and performing calculations, and controlling the hydraulic pump station to output the test status. The test operation station is used to control the hydraulic pump station and electrical control cabinet; The integrated test bench interacts with the tooling table via a connector panel to exchange hydraulic oil and communication control signals; The integrated test bench is also connected to the power cable via a connector panel.

2. The system according to claim 1, characterized in that: The tooling table includes: The test bench serves as a platform support; Eight clamp sliding guide rails are fixed in pairs on the test hydraulic booster tank mounting plate; A set of test hydraulic booster tank fixing brackets are installed on two adjacent clamp sliding guide rails, and a test hydraulic booster tank is fixed together by a set of test hydraulic booster tank fixing brackets; The clamp guide rail locking device is used to fix the test hydraulic booster tank fixing frame; A micro switch sliding rail is installed at each of the four corner edges of the upper surface of the test bench, parallel to the clamp sliding rail; Two microswitches are installed on each microswitch sliding rail, and two microswitch rail locking devices are used to lock the two microswitches respectively; The hydraulic oil tank quick-connect coupling panel includes an oil reservoir supply interface, a pressure boosting chamber supply interface, a return interface, and a control signal interface.

3. The system according to claim 2, characterized in that: The tooling also includes: a control valve assembly, comprising a flow regulating valve, a first solenoid valve, a second solenoid valve, a proportional relief valve, a first directional solenoid valve, a first pressure sensor, and a second pressure sensor; The inlet of the flow regulating valve is connected to the oil supply interface of the oil storage chamber on the quick-change connector panel of the hydraulic oil tank, the outlet of the flow regulating valve is connected in series with the first solenoid valve, and the outlet of the first solenoid valve is connected to the first pressure sensor. The second solenoid valve is connected in parallel with the proportional relief valve. Its inlet is connected to the outlet of the first solenoid valve, and its outlet is connected to the return oil interface on the quick-connect coupling panel of the pressure oil tank. The first interface of the third solenoid valve is connected to the oil supply interface of the pressure chamber of the quick-change connector panel of the hydraulic oil tank, the second interface of the third solenoid valve is connected to the oil return interface of the quick-change connector panel of the hydraulic oil tank, and the third interface of the third solenoid valve is connected in series with the second pressure sensor.

4. The system according to claim 3, characterized in that: The tooling table also includes a waste oil collection tank for collecting waste oil during testing.

5. The system according to claim 1, characterized in that: The hydraulic pump station includes a hydraulic oil tank assembly, an oil storage chamber motor pump unit, a booster chamber motor pump unit, a pump control valve assembly, and hydraulic pipelines, providing a hydraulic oil source for the test.

6. The system according to claim 5, characterized in that: The hydraulic oil tank assembly includes: oil tank, temperature sensor, level gauge, air filter, suction filter, return filter, and radiator; Temperature sensor, level gauge, and air filter are installed on the oil tank. Suction filter is installed on the oil tank outlet hydraulic line and connected to the pump. Return filter is connected in series with radiator and installed on the oil tank inlet hydraulic line. When the temperature value reported by the temperature sensor rises to 50°C, the heat sink starts to work and dissipate heat.

7. The system according to claim 5, characterized in that: The oil storage chamber motor pump set contains two sets of motor pump sets connected in parallel, one of which serves as a redundant backup to provide oil source for the oil storage chamber of the test hydraulic booster tank; the booster chamber motor pump set contains two sets of motor pump sets connected in parallel, one of which serves as a redundant backup to provide oil source for the booster chamber of the test hydraulic booster tank.

8. The system according to claim 5, characterized in that: The pump control valve group includes a check valve, a first pressure oil filter, a direct-acting relief valve, a manual shut-off valve, a pilot relief valve, a reversing solenoid valve, and a second pressure oil filter, which control the flow rate, pressure, and direction of the hydraulic oil source. The outlet of the one-way valve is connected to the first pressure oil filter; The outlet of the check valve is connected to the inlet of the direct-acting relief valve and the inlet of the manual shut-off valve. The pilot relief valve is connected in parallel with the reversing solenoid valve, the inlet is connected to the second pressure oil filter, and the outlet is connected to the outlet of the direct-acting relief valve.

9. A test method for a helicopter hydraulic booster tank, implemented based on the system according to any one of claims 1-8, characterized in that: The sealing test procedure is as follows: Step 1: Fixing and connecting the four hydraulic booster tanks under test; Step 2: Select the test item through the test operation station: sealing test; Step 3: Enter the sealing test interface and set the required test parameters; Step 4: Start the oil storage chamber motor pump set and the booster chamber motor pump set; Step 5: Adjust the system pressure to the required test pressure using a direct-acting relief valve, manual shut-off valve, flow regulating valve, proportional relief valve, and pilot-operated relief valve; Step Six: Start the test control program of the test operation station to complete the test. The first and second solenoid valves are energized at the same time, the third solenoid valve is de-energized, and the piston rod of the hydraulic booster tank under test extends. Step 7: After the piston rod of the hydraulic booster tank under test has fully extended, adjust the manual shut-off valve clockwise and observe the value shown by the first pressure sensor. When the value reaches 0.25MPa±0.05MPa, stop adjusting the manual shut-off valve and observe for 3 minutes. Step 8: After observing for 3 minutes, check the hydraulic booster tank of the test subject for leaks; Step 9: The first and second solenoid valves are simultaneously de-energized, the third solenoid valve is energized, and the piston rod of the hydraulic booster tank under test retracts. Step 10: After the piston rod of the hydraulic booster tank under test has fully retracted into place, observe the value shown by the second pressure sensor, adjust the pilot relief valve handle to the value shown as 10MPa, stop adjusting when the value reaches 10MPa, and observe for 3 minutes. Step 11: After observing for 3 minutes, check the hydraulic booster tank of the test subject for leaks.

10. A test method for a helicopter hydraulic booster tank, implemented based on the system according to any one of claims 1-9, characterized in that, The pressurization test process is as follows: Step 1: Fixing and connecting the four hydraulic booster tanks under test; Step 2: Select the test item through the test operation station: pressurization pressure test; Step 3: Enter the pressure boosting test interface and set the required test parameters; Step 4: Start the oil storage chamber motor pump set and the booster chamber motor pump set; Step 5: Adjust the system pressure to the required test pressure using a direct-acting relief valve, manual shut-off valve, flow regulating valve, proportional relief valve, and pilot-operated relief valve; Step Six: Start the test control program of the test operation station to complete the test. The first and second solenoid valves are energized at the same time, the third solenoid valve is de-energized, and the piston rod of the hydraulic booster tank under test extends until it is fully extended. Step 7: The first and second solenoid valves are simultaneously de-energized, the third solenoid valve is energized, and the piston rod of the hydraulic booster tank under test retracts. Step 8: Observe the value shown by the second pressure sensor and adjust the pilot relief valve handle to the value shown as 10MPa; Step 9: After the hydraulic tank retracts for 3-5 seconds, energize the second solenoid directional valve. At this time, the hydraulic tank should remain stationary. Observe whether the value shown by the first pressure sensor is 0.25MPa±0.05MPa. Step 10: The second solenoid directional valve is de-energized. Repeat step 9 twice and check the results. The durability test process is as follows: Step 1: Fixing and connecting the four hydraulic booster tanks under test; Step 2: Select the test item through the test operation station: durability test; Step 3: Enter the durability test interface and set the required test parameters; Step 4: Start the oil storage chamber motor pump set and the booster chamber motor pump set; Step 5: Adjust the system pressure to the required test pressure using a direct-acting relief valve, manual shut-off valve, flow regulating valve, proportional relief valve, and pilot-operated relief valve; Step Six: Start the test control program on the test operation station to complete the test; Step 7: When the first and second solenoid valves are energized simultaneously and the third solenoid valve is de-energized, the oil inlet chamber of the hydraulic booster tank under test enters the booster chamber and the oil outlet chamber returns oil, and the piston rod of the tank extends; when the piston rod triggers the micro switch, the reversal is controlled by the set program. Step 8: The first and second solenoid valves are simultaneously de-energized, the third solenoid valve is energized, the oil storage chamber of the tested hydraulic booster tank returns oil to the booster chamber, and the piston rod of the tank retracts; when the piston rod triggers the micro switch, the reverse direction is controlled by the set program, returning to step 7; Step Nine: The test control program automatically repeats Steps Seven and Eight until the set number of cycles is reached.

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