Method for Formulating Aeroengine Bench Endurance Test Procedure and Test Method

Abstract

The present invention discloses a method for formulating an endurance test procedure and a test method for an aero-engine test bench. Among them, the formulating method includes: obtaining test contents according to airworthiness requirements; classifying test units that need to be tested under the same operating state in the test contents into the same test group. The test plan generated by using the above formulating method can, on the basis of meeting airworthiness standards, greatly simplify the test run process, quickly complete time accumulation, shorten the test run cycle of the aero-engine, reduce the number of times of test bench adjustment and start-up, thereby reducing the test run cost and the risk of equipment damage.

Description

Technical Field

[0001] The present invention relates to the field of aero-engine test runs, and particularly to a method for formulating a bench endurance test procedure and a test method for an aero-engine. Background Art

[0002] In recent years, the research and development of domestic large bypass ratio civil turbofan aero-engines has developed rapidly. During its development process, civil aero-engines must go through the process of airworthiness certification; and during the airworthiness certification process, the engines under model development must undergo bench endurance test runs for a certain period of time.

[0003] The redline speeds defined for the maximum continuous and takeoff states of large bypass ratio turbofan civil aero-engines are the same, but the redline gas temperatures and full rated thrust or power values are different; therefore, different test pieces and / or test equipment modifications are required for the operation processes of the triple redline states in the maximum continuous and takeoff states to simulate the corresponding engine states. If the test runs are carried out strictly in accordance with the test run procedures stipulated in the airworthiness regulations, multiple test piece and / or test equipment modifications will have to be carried out during each test run cycle; so it is impractical in the actual test operation process. Multiple modifications or replacements will increase the risk of damage to the test pieces or test equipment, and will also increase the starting times of the bench endurance test, ultimately resulting in a waste of a large amount of human and material resources and an increase in the time cycle cost. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to overcome the defects in the prior art that the bench endurance test operation is cumbersome, the consumption of human and material resources is large, and the test cycle is long, and to provide a method for formulating a bench endurance test procedure and a test method for an aero-engine.

[0005] The present invention solves the above technical problem through the following technical solutions:

[0006] A method for formulating a bench endurance test procedure for an aero-engine, the formulating method comprising:

[0007] Obtaining test contents according to airworthiness requirements;

[0008] Classifying the test units that need to be tested under the same operating state in the test contents into the same test group,

[0009] wherein, classifying the test units that need to be tested under the first operating state in the test contents into the first test group, and classifying the test units that need to be tested under the second operating state in the test contents into the second test group;

[0010] Formulating the test units in the first test group into a continuous test process, and formulating the test units in the second test group into a continuous test process.

[0011] In this solution, the test units within the same test group require the same operating state. Therefore, when the test bench is adjusted to the corresponding mode and runs to the corresponding operating state, cyclic tests of multiple test units can be continuously carried out. During the test process, there is no need to stop the vehicle in the middle to adjust the test bench. After all the test units in a test group are completed, then stop and adjust the test bench so that the test bench is adjusted to other test modes. When the test bench runs to another operating state, then conduct tests on the test units of the corresponding test group. Therefore, the test plan generated by the above-mentioned formulation method can greatly simplify the test run process on the basis of meeting the airworthiness standards, quickly complete the time accumulation, shorten the test run cycle of the aero-engine, reduce the number of times of test bench adjustment and startup, and thus reduce the test run cost and the risk of equipment damage.

[0012] Preferably, the process of formulating the test units in the first test group into a continuous test process and formulating the test units in the second test group into a continuous test process includes:

[0013] Within the same test group, after the cyclic test of one test unit is completed, then conduct the cyclic test of another different test unit.

[0014] Preferably, the process of formulating the test units in the first test group into a continuous test process and formulating the test units in the second test group into a continuous test process includes:

[0015] Within the same test group, after multiple test units sequentially complete one cycle of testing, then sequentially conduct the next cycle of testing until all cycles are completed.

[0016] Preferably, the first operating state and the second operating state are the takeoff state and the maximum continuous state respectively.

[0017] A test method for a durability test program of an aero-engine test bench

[0018] Formulate a test program according to the formulation method of the durability test program of the aero-engine test bench as described above;

[0019] Adjust the test bench so that the test bench is in the first test mode, and the first test mode corresponds to the first operating state;

[0020] Start the test bench so that the test bench runs to the first operating state in the first test mode. When the test bench reaches the first operating state, conduct tests on the test units in the first test group. After the test units in the first test group are completed, stop the operation of the test bench;

[0021] Adjust the test bench so that the test bench is in the second test mode, and the second test mode corresponds to the second operating state;

[0022] Start the test bench so that the test bench runs to the second operating state in the second test mode. When the test bench reaches the second operating state, conduct the tests on the test units within the second test group. When the tests on the test units within the second test group are completed, stop the operation of the test bench.

[0023] In this solution, the test units that need to be tested in the same operating state are concentrated and continuously tested. Therefore, after the test bench is adjusted once, the engine can continuously conduct the test runs of multiple test units, thereby reducing the number of adjustments of the test bench and the number of engine starts, simplifying the test run procedure, reducing the test run cycle, and quickly completing the work assessment of the cumulative endurance test while meeting the airworthiness requirements.

[0024] Preferably, when a test unit runs for a predetermined time in the first operating state or the second operating state, the test bench stops running.

[0025] Preferably, when the test bench is running in the first operating state, if it is detected that the state of the test bench deviates from the first operating state, the timing is stopped;

[0026] Or, when the test bench is running in the second operating state, if it is detected that the state of the test bench deviates from the second operating state, the timing is stopped.

[0027] Preferably, the test bench is equipped with an accurate timer. When the first test state runs to the first operating state or when the second test state runs to the second operating state, the accurate timer starts timing.

[0028] Preferably, based on the time recorded by the accurate timer, a time cumulative record of each test unit is formed.

[0029] The positive and progressive effects of the present invention are as follows: In the method for formulating the aero-engine bench endurance test procedure of the present invention, test units that need to be tested under the same operating conditions are divided into the same test group. Therefore, when the bench is adjusted to the corresponding mode and runs to the corresponding operating state, cyclic tests of multiple test units can be continuously carried out, and there is no need to stop the vehicle midway to adjust the bench during the test process. Therefore, the test plan generated by the above-mentioned formulation method can, on the basis of meeting the airworthiness standards, greatly simplify the test drive process, quickly complete the time accumulation, shorten the aero-engine test drive cycle, reduce the number of bench adjustments and starts, and thereby reduce the test drive cost and the risk of equipment damage. In the test method of the aero-engine bench endurance test procedure of the present invention, through the test procedure obtained by using the above-mentioned formulation method for testing, after the bench is adjusted once, the engine can continuously carry out test drives of multiple test units, and then the bench is adjusted again to carry out tests of multiple test units in another test group, thereby reducing the number of bench adjustments and engine starts, simplifying the test drive procedure, reducing the test drive cycle, and quickly completing the work assessment of the cumulative endurance test while meeting the airworthiness requirements. The test drive cycle spectrum formulated by using the formulation method of the present invention can complete the work assessment of the test cumulative endurance test without changing the harshness of the original test procedure, without affecting the actual assessment effect, and meeting the requirements of airworthiness regulations. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 Schematic diagram of the test drive procedure for a single cycle test of an aero-engine for airworthiness regulations.

[0031] Figure 2 For Figure 1 Schematic diagram of multiple test units obtained by splitting the test drive procedure.

[0032] Figure 3 Flow chart of the method for formulating the aero-engine bench endurance test procedure according to an embodiment of the present invention.

[0033] Figure 4 Flow chart of the test method of the aero-engine bench endurance test procedure according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0034] The present invention will be further described below by way of examples, but the present invention is not limited to the scope of the described examples.

[0035] This embodiment provides a method for formulating an aero-engine bench endurance test procedure. Refer to Figure 1 As shown, in the CCAR 33.87 (or FAR33.87) airworthiness regulations, the specified 150hr bench endurance test procedure includes 25 cycles, and in each cycle, the engine needs to experience Figure 1The state shown in. According to Figure 3 The specified method shown, each cycle is decomposed into 5 parts, so that the 150-hr test program is decomposed into 125 independent test program units, and the requirements of each test program unit fully meet the requirements of airworthiness regulations. It can be understood that in other embodiments, according to the actual situation, each cycle can also be decomposed into other numbers of test units.

[0036] Specifically, referring to Figure 2 As shown, the cumulative test time for each cycle is 6 hr, and each cycle contains 5 parts, which are respectively named test units A to E. Among them, test unit A includes a 60-min takeoff and idle state process (consisting of 6 cycles, each cycle consisting of an alternating 5-min rated takeoff thrust and 5-min ground idle thrust); test unit B consists of a 30-min takeoff (or maximum continuous) thrust state (including 10 takeoffs and 15 maximum continuous); test unit C consists of a 90-min maximum continuous thrust state; test unit D consists of 15 gradually approaching fan speeds, with the fan speed set between maximum continuous and minimum ground idle, and each speed state is 10 min; test unit E consists of a 30-min acceleration and deceleration operation (including 6 acceleration and deceleration operation combination cycles, each cycle consisting of accelerating from idle thrust to takeoff thrust and then decelerating from takeoff thrust to idle thrust; maintaining 30 s and 4.5 min in takeoff and idle states respectively).

[0037] Among them, test units A, B, and E all need to be completed when the test bench is in the takeoff state (the first operating state), and test units C and D all need to be completed when the test bench is in the maximum continuous state (the second operating state). Therefore, it is possible not to install Figure 1 The given test program in is carried out in the order of A - B - C - D - E. Otherwise, it is impossible for a civil high-bypass ratio aeroengine to be completed on a test bench using a set of hardware equipment according to its own design characteristics, and it is necessary to continuously adjust and replace the equipment on the test bench to meet the state requirements of the corresponding test units. Test units A, B, and E can be compiled into the first test group, and test units C and D can be compiled into the second test group. When the test bench is in the takeoff state, the tests of the first test group are carried out, and when the test bench is in the maximum continuous state, the tests of the second test group are carried out, thereby simplifying the test process, reducing the test cycle, and improving the efficiency.

[0038] When formulating the test procedure, 25 independent (A - B - E) combined cycle test runs can be carried out first; then 25 independent (C - D) combined cycle test runs can be carried out. This order of test runs is for the minimum number of modifications (or replacements) of test pieces and test equipment; that is, only 1 modification or replacement is required, which is a time - and labor - saving test order arrangement. Prepare the equipment required for the endurance test according to the test requirements, configure the test procedure requirements according to the possible engine technical states and test equipment needs in a classified manner, and confirm the possible test procedures under each set of hardware. After sorting out the corresponding test procedure segments according to the different required equipment, arrange them in the required order. For example, one cycle in test unit A can be carried out first, followed by one cycle in test unit B and one cycle in test unit E, that is, the single cycles of A - B - E are executed 25 times in a loop. Or, after the 25 cycles in test unit A are completed, the 25 cycles in test unit B and E can be executed respectively. Or, when the take - off state is reached online, the workflow of A - B - E - D can be followed, and then the program content of part C can be completed separately. Or, the B - A program can be followed, then the program content of part E - D can be completed, and finally the test procedure of part C can be completed. This can achieve the maximum utilization of equipment, simplify the operation of test equipment, and reduce the workload of staff as much as possible.

[0039] According to the 125 independent test units divided, confirm the requirements for the independent unit to enter the state and the boundary conditions for completing the state work.

[0040] This embodiment also provides a test method for the aero - engine bench endurance test procedure. Refer to Figure 4 As shown, after formulating the test procedure, during the test, according to the formulated order, complete the content of each test run procedure segment and accumulate the assessment time of the test working state.

[0041] Formulate a clear state confirmation list for each independent test unit, and set an accurate timer for the supporting confirmation list. When the test state meets all requirements (i.e., the working states required in the state confirmation list), the accurate timer starts timing; when the state reaches the specified program time, exit this working state, and the time of each working state is accumulated.

[0042] To ensure the authenticity and accuracy of the 125 independent test procedure units, set an accurate timer during the confirmation process of each independent test procedure state to avoid manual operation and implement the automated calculation and accumulation of data.

[0043] Each independent test running program unit of each division accumulates the status working time using an accurate timer. In actual work, a technical prevention method is adopted to determine the status to avoid confusion in the working status and neglect of details. After the engine reaches the required working status, it immediately enters the comparison link between the actual status and the specified defined status, and the status working time counting starts only when the defined requirements are met. During the test, once there is a situation that does not meet the initial defined requirements, the timer immediately stops the cumulative working time of this status instantaneously. For example, when the test bench is running in the first operating state, if it is detected that the status of the test bench deviates from the original first operating state, the timing is stopped. Similarly, when the test bench is running in the second operating state, if it is detected that the status of the test bench deviates from the second operating state, the timing is stopped. It is not until all status definition requirements are met again that the timer will resume the cumulative counting of the status working time to ensure that the cumulative working status time is true, accurate and traceable. After completing the test of each arranged independent test running program unit and completing the cumulative calculation of the working status assessment time specified in all test running programs, a relevant cumulative record of the working status time is formed. The test assessment of 125 independent test program units is completed based on the record of the accurate timer, and then the 150hr test bench endurance test running is completed.

[0044] Although the specific embodiments of the present invention have been described above, those skilled in the art should understand that this is only for illustration. The protection scope of the present invention is defined by the appended claims. Without departing from the principles and essence of the present invention, those skilled in the art can make various changes or modifications to these embodiments, but these changes and modifications all fall within the protection scope of the present invention.

Claims

1. A method for formulating a durability test procedure for an aero-engine test bench, characterized in that, The formulation method includes: According to airworthiness requirements, obtain the test content. The test content includes multiple cycles, each cycle includes 5 test units. The first test unit includes the takeoff and idle state processes. The second test unit includes the takeoff thrust state or the maximum continuous thrust state. The third test unit includes the maximum continuous thrust state. The fourth test unit includes multiple fan speeds gradually approaching, and the fan speed is set between the maximum continuous and the minimum ground idle. The fifth test unit includes acceleration and deceleration operations. Classify the test units that need to be tested under the same operating state in the test content into the same test group. Among them, classify the test units that need to be tested under the first operating state in the test content into the first test group, and classify the test units that need to be tested under the second operating state in the test content into the second test group. The first operating state and the second operating state are the takeoff state and the maximum continuous state respectively. Compile the test units in the first test group into a continuous test process, and compile the test units in the second test group into a continuous test process.

2. The method for formulating the endurance test procedure of an aero-engine test stand according to claim 1, characterized in that, The step of compiling the test units in the first test group into a continuous test process and compiling the test units in the second test group into a continuous test process includes: Within the same test group, after a test unit has completed a cyclic test, then conduct a cyclic test of another different test unit.

3. The method for formulating the endurance test procedure of an aero-engine test bench according to claim 1, wherein The step of compiling the test units in the first test group into a continuous test process and compiling the test units in the second test group into a continuous test process includes: Within the same test group, after multiple test units have sequentially completed one cycle of testing, then sequentially conduct the next cycle of testing until all cycles are completed.

4. The method for formulating the endurance test procedure of an aero-engine test bench according to claim 1, characterized in that, Compile the first test unit, the second test unit, and the fifth test unit into the first test group, and compile the third test unit and the fourth test unit into the second test group.

5. A test method for an aeroengine bench endurance test program, characterized in that Formulate a test program according to the formulation method of the aeroengine bench endurance test program described in any one of claims 1 to 4; Adjust the bench so that the bench is in the first test mode, and the first test mode corresponds to the first operating state; Start the bench so that the bench runs in the first test mode to the first operating state. When the bench reaches the first operating state, conduct the test of the test units in the first test group. When the test units in the first test group are completed, stop the operation of the bench; Adjust the bench so that the bench is in the second test mode, and the second test mode corresponds to the second operating state; Start the bench so that the bench runs in the second test mode to the second operating state. When the bench reaches the second operating state, conduct the test of the test units in the second test group. When the test units in the second test group are completed, stop the operation of the bench.

6. The test method for an aeroengine bench endurance test program according to claim 5, characterized in that When a test unit runs for a predetermined time under the first operating state or the second operating state, the bench stops running.

7. The test method of the aero-engine bench endurance test procedure according to claim 5, characterized in that: When the bench is operating in the first operating state or the second operating state, if it is detected that the state of the bench deviates from the original operating state, the timing is stopped.

8. The test method of the aero-engine bench endurance test procedure according to claim 7, characterized in that: After the state of the bench deviates from the original operating state, the bench is adjusted to restore the bench to the original operating state, and then the timing continues.

9. The test method of the aero-engine bench endurance test procedure according to any one of claims 6 to 8, characterized in that: The bench is equipped with a timer, and when the first test mode runs to the first operating state or when the second test mode runs to the second operating state, the timer starts timing.

10. The test method of the aero-engine bench endurance test procedure according to claim 9, characterized in that: Taking the time recorded by the timer as the standard, a time cumulative record of each test unit is formed.

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