An online detection system for oil wear particles in aircraft engines

Abstract

The present invention discloses an online aircraft engine oil wear particle detection system, characterized by comprising a chassis, a magnetoelectric sensor, a signal processing / drive module, a control module, and a power supply. The magnetoelectric sensor includes an excitation coil and a detection coil. The signal processing / drive module processes the raw signal from the magnetoelectric sensor. The control module includes a single-chip microcomputer, an FPGA, a clock, an ADC, a comparator, and an EEPROM lookup table. Compared to existing technologies, the present invention offers advantages in that it utilizes an all-electronic circuit detection method for real-time detection and processing of particle signals, eliminating the need for a DSP and supporting software, improving particle detection sensitivity, and enhancing system reliability.

Description

Technical Field

[0001] The present invention relates to the field of aviation engines, in particular to an online oil wear particle detection system for aircraft engines. Background Art

[0002] The normal operation of the engine is the basis for ensuring the normal flight of the aircraft. In order to monitor whether the engine is running healthily, it is necessary to install a variety of health detection sensors on the engine. The oil wear particle online detection system is composed of sensors, special cables and signal processing units, such as Figure 1 The basic process is to install a sensor on the engine lubricating oil pipeline, detect wear particle signals in the oil flowing through the sensor online, and transmit the sensor detection signal to the signal processing unit via a dedicated cable. The signal processing unit then analyzes the sensor detection signal and infers the wear particle information in the oil. If abnormal wear particles are detected, an alarm is required in a timely manner. Normal wear particles are analyzed and used as the basis for engine health assessment. This system belongs to the engine health detection category.

[0003] Online oil wear particle detection systems are broadly categorized into two types: civil and aviation. Civil applications are primarily used for monitoring the health of marine and wind turbine engines, while aviation applications primarily focus on aircraft engine health monitoring. Aviation applications, due to operating environment constraints, require a wider temperature range, higher sensitivity, and higher reliability than civil applications.

[0004] Environmental conditions for normal operation of aircraft engines:

[0005] (1) Civil airliners generally fly at an altitude of 6,000 to 12,600 meters, and the temperature at high altitude is around -55°C;

[0006] (2) The temperature of the lubricating oil in an aircraft engine can reach up to 180°C. After being transmitted to the signal processing unit through a dedicated cable, the temperature of the connector area of ​​the signal processing unit may also reach or exceed 120°C.

[0007] (3) The maximum flow rate of aircraft engine lubricating oil exceeds 90L / min, which is much greater than the flow rate of ship engine lubricating oil;

[0008] (4) Aircraft engines have weight restrictions on the auxiliary systems they can carry. If lighter equipment can be provided, it will be more advantageous with the same functional performance.

[0009] Based on the actual use environment of aircraft engines, in order to achieve the required functions and normal and reliable operation, the corresponding detection system should also meet the actual working environment starting from the lowest-level components.

[0010] Disadvantages of existing technologies in aircraft engine applications:

[0011] (1) The DSP control module in the signal processing unit typically uses a DSP chip for automotive applications. The operating temperature range of automotive chips is -40°C to 125°C, which poses a risk of failure during use in aircraft engines. Aviation-grade DSP chips are very limited, have poor interchangeability, and are expensive.

[0012] (2) The DSP control module in the signal processing unit typically uses a DSP chip for automotive applications. The operating temperature range of automotive chips is -40°C to 125°C, which poses a risk of failure during use in aircraft engines. Aviation-grade DSP chips are very limited, have poor interchangeability, and are expensive.

[0013] (3) DSP chips have a certain delay in signal processing, poor real-time performance, and a certain amount of missed detection. During normal operation, the flow rate of aircraft engine lubricating oil is higher than that of civilian engine lubricating oil. The engine is the core of the aircraft to ensure normal flight. If minor faults can be detected in time, it will help to make timely predictions and increase the time for handling, thus providing an additional guarantee for flight safety.

[0014] (4) The clock signal of the DSP chip has poor resistance to high-frequency interference.

[0015] (5) The existing products are relatively large in size and heavy in weight. Summary of the Invention

[0016] The technical problem to be solved by the present invention is to overcome the above technical defects and provide a sensor that uses a full electronic circuit detection method to detect and process particle signals in real time, does not require DSP and supporting software, and has correspondingly improved particle detection sensitivity.

[0017] To solve the above problems, the technical solution of the present invention is as follows: an online oil wear particle detection system for an aircraft engine, comprising a chassis, a magnetoelectric sensor, a signal processing / drive module, a control module, and a power supply. The online oil wear particle detection system is composed of a sensor, a dedicated cable, and a signal processing / drive module unit;

[0018] The signal processing / driving module completes the processing of the original signal from the magnetoelectric sensor, and the signal processing / driving module completes signal pre-amplification, band-pass filtering, phase-locked amplification, low-pass filtering, DC removal, post-stage shaping amplification, peak detection, system self-test, phase shifting and driving circuit, etc.

[0019] The control module includes a single chip microcomputer, an FPGA, a clock, an ADC, a comparator and a lookup table EEPROM.

[0020] Furthermore, the chassis supports explosion-proof, EMI-proof, and heat dissipation, and the connectors on the chassis all use military standards.

[0021] Furthermore, the excitation coil forms a spatially symmetrical reverse excitation electromagnetic field when a high-frequency current flows through it, and the total inductance of the excitation coil and the detection coil is about 110 μH.

[0022] Furthermore, the FPGA provides functions such as generation of various clocks, clock phase shifting, and system self-test;

[0023] The ADC converts the signal from the peak detection circuit into a numerical signal for processing by the single chip microcomputer;

[0024] The single chip microcomputer is responsible for the control, management, communication, ADC data processing and external display of the entire system;

[0025] The comparator is used to compare the signals of the I and Q channels with the preset thresholds and output TTL pulses;

[0026] The lookup table EEPROM is used to store system calibration data and calculate the relationship between peak detection voltage and particle size.

[0027] Furthermore, the excitation coil and the detection coil include lead wires, and the lead wires are all shielded wires.

[0028] Furthermore, the working environment of the aircraft engine oil wear particle online detection system is:

[0029] Working altitude: (-600~12600) meters

[0030] Sensor working environment temperature: (-55~180)℃

[0031] Signal processing unit working environment temperature: (-55~125)℃

[0032] Working environment pressure: 20~110kPa

[0033] Working environment vibration: 10-50Hz: 3mm (displacement); 50-300Hz: 15g (acceleration).

[0034] Furthermore, there is one control module, and there is at least one signal processing / driving module and magnetoelectric sensor.

[0035] The advantages of the present invention compared with the existing technology are:

[0036] (1) The drive and signal processing module uses a full electronic circuit detection method to detect and process particle signals in real time, thereby improving the particle detection sensitivity;

[0037] (2) The control module uses a combination of FPGA and MCU chips to replace the DSP chip, integrating the analysis of iron particles and non-iron particles, reducing the number of electronic circuits for signal analysis, reducing size and weight;

[0038] (3) Electronic circuit chips, FPGA, and MCU chips are available in multiple brands and models that support temperatures ranging from -55°C to 150°C, improving the reliability and sustainability of the system.

[0039] Chassis: supports explosion-proof, EMI-proof, heat dissipation, etc. The connectors are all made to military standards, can prevent EMI, have good shielding, and are easy to test and install.

[0040] Magnetoelectric sensor: A magnetoelectric sensor uses the principle of electromagnetic induction to convert the input motion velocity into an induced potential output in a coil. It directly converts the mechanical energy of the object being measured into an electrical signal output, requiring no external power supply for operation, and is a typical passive sensor. Because this sensor has a high output power, the secondary instrument circuit used is greatly simplified. The magnetoelectric sensor of the present invention includes an excitation coil and a detection coil. The excitation coil consists of two inductors and coils of identical structure but oppositely wound wires. When a high-frequency current flows through it, a spatially symmetrical oppositely excited electromagnetic field is formed. The total inductance of the two coils is approximately 110 μH. Resonant capacitors are connected to both ends of the coil to maximize the excitation current at resonance.

[0041] Signal processing / drive module: The signal processing module transmits DC voltage or current signals through isolation, converting them into the required signals for other instruments. It can be used in conjunction with unit combination instruments and systems such as DCS and PLC to provide field instrument signal isolation, signal conversion, signal distribution, and signal processing, thereby improving the anti-interference ability of industrial production process automatic control systems and ensuring system stability and reliability.

[0042] Power supply: The power supply of this invention is converted from 12VDC. The main power supply is + / -15V for all analog circuits and excitation drive circuits; the power supply is +3.3V for digital circuits such as microcontrollers, FPGAs, and EEPROMs; the power supply is +5V for comparators and other circuits that require 5V power supply, which can be used by multiple circuits. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 The present invention is a system structure diagram of an online detection system for oil wear particles of an aircraft engine.

[0044] Figure 2 This is a diagram of the internal structure and electrical connections of a magnetoelectric sensor for an on-line oil wear particle detection system for an aircraft engine according to the present invention.

[0045] Figure 3The present invention is a flow chart of a signal processing / driving module of an online oil wear particle detection system for an aircraft engine.

[0046] Figure 4 This is a functional description diagram of an online oil wear particle detection system for an aircraft engine according to the present invention.

[0047] Figure 5 This is a schematic diagram of the structure of an online detection system for oil wear particles in an aircraft engine according to the present invention. Figure 1 .

[0048] Figure 6 This is a schematic diagram of the structure of an online detection system for oil wear particles in an aircraft engine according to the present invention. Figure 2 .

[0049] Figure 7 This is a schematic diagram of the structure of an online detection system for oil wear particles in an aircraft engine according to the present invention. Figure 3 . DETAILED DESCRIPTION

[0050] The specific embodiments of the present invention are further described below with reference to the accompanying drawings, wherein the same parts are represented by the same reference numerals.

[0051] It should be noted that the words "front", "rear", "left", "right", "up" and "down" used in the following description refer to directions in the accompanying drawings, and the words "inside" and "outside" refer to directions toward or away from the geometric center of a specific component, respectively.

[0052] In order to make the contents of the present invention more clearly understood, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0053] Example 1

[0054] An online oil wear particle detection system for aircraft engines includes a chassis, a magnetoelectric sensor, a signal processing / drive module, a control module, and a power supply. The oil wear particle online detection system is composed of a sensor, a dedicated cable, and a signal processing / drive module unit. For civil aircraft engines, the detector and processing unit can be combined.

[0055] The signal processing / driving module completes the processing of the original signal from the magnetoelectric sensor, and the signal processing / driving module completes signal pre-amplification, band-pass filtering, phase-locked amplification, low-pass filtering, DC removal, post-stage shaping amplification, peak detection, system self-test, phase shifting and driving circuit, etc.

[0056] The control module includes a single chip microcomputer, an FPGA, a clock, an ADC, a comparator and a lookup table EEPROM.

[0057] The chassis supports explosion-proof, EMI-proof and heat dissipation, and the connectors on the chassis all use military standards.

[0058] The excitation coil forms a spatially symmetrical reverse excitation electromagnetic field when a high-frequency current flows through it. The total inductance of the excitation coil and the detection coil is about 110 μH.

[0059] The FPGA provides functions such as generation of various clocks, clock phase shifting, and system self-test;

[0060] The ADC converts the signal from the peak detection circuit into a numerical signal for processing by the single chip microcomputer;

[0061] The single chip microcomputer is responsible for the control, management, communication, ADC data processing and external display of the entire system;

[0062] The comparator is used to compare the signals of the I and Q channels with the preset thresholds and output TTL pulses;

[0063] The lookup table EEPROM is used to store system calibration data and calculate the relationship between peak detection voltage and particle size.

[0064] The power supply is converted from 12VDC. The main + / -15V is used for all analog circuits and excitation drive circuits:

[0065] The power supply is +3.3V and is used for digital circuits such as microcontrollers, FPGAs, and EEPROMs;

[0066] The power supply is +5V and is used for comparators and other circuits that require 5V power supply.

[0067] The working environment of the aircraft engine oil wear particle online detection system is:

[0068] Working altitude: (-600~12600) meters

[0069] Sensor working environment temperature: (-55~180)℃

[0070] Signal processing unit working environment temperature: (-55~125)℃

[0071] Working environment pressure: 20~110kPa

[0072] Working environment vibration: 10-50Hz: 3mm (displacement); 50-300Hz: 15g (acceleration).

[0073] There is one control module, and there is at least one signal processing / driving module and magnetoelectric sensor.

[0074] The sensor model is LD-ODM-2000-40, the through-hole diameter is Φ40mm, the interface diameter is Φ39mm, the detectable size range is: a. ferromagnetic particles: 300-1500μm, b. non-magnetic particles: 1000-1500μm, and the minimum flow rate is 3L / min.

[0075] Example 2

[0076] The working environment of the aircraft engine oil wear particle online detection system is:

[0077] Working altitude: (-600~12600) meters

[0078] Sensor working environment temperature: (-55~180)℃

[0079] Signal processing unit working environment temperature: (-55~125)℃

[0080] Working environment pressure: 20~110kPa

[0081] Working environment vibration: 10-50Hz: 3mm (displacement); 50-300Hz: 15g (acceleration).

[0082] The sensor model is LD-ODM-2000-30, the through-hole diameter is Φ27mm, the interface diameter is Φ26mm, and the detectable size range is: a. ferromagnetic particles: 200-1000μm, b. non-magnetic particles: 600-1500μm, and the minimum flow rate is 10L / min.

[0083] Example 3

[0084] The working environment of the aircraft engine oil wear particle online detection system is:

[0085] Working altitude: (-600~12600) meters

[0086] Sensor working environment temperature: (-55~180)℃

[0087] Signal processing unit working environment temperature: (-55~125)℃

[0088] Working environment pressure: 20~110kPa

[0089] Working environment vibration: 10-50Hz: 3mm (displacement); 50-300Hz: 15g (acceleration).

[0090] There is one control module, and there is at least one signal processing / driving module and magnetoelectric sensor.

[0091] The sensor model is LD-ODM-2000-20, the through-hole diameter is Φ19mm, the interface diameter is Φ18mm, the detectable size range is: a. ferromagnetic particles: 120-1000μm, b. non-magnetic particles: 400-1500μm, and the minimum flow rate is 8L / min.

[0092]

[0093]

[0094] The present invention and its embodiments are described above. This description is not restrictive. The drawings show only one embodiment of the present invention, and the actual structure is not limited thereto. In short, if a person skilled in the art is inspired by this and, without departing from the purpose of the present invention, designs structures and embodiments similar to this technical solution without inventiveness, they shall fall within the scope of protection of the present invention.

Claims

1. An online detection system for oil wear particles in aircraft engines, characterized by: Includes chassis, magnetoelectric sensor, signal processing / drive module, control module and power supply; The signal processing / driving module completes the processing of the original signal from the magnetoelectric sensor, and the signal processing / driving module completes signal pre-amplification, band-pass filtering, phase-locked amplification, low-pass filtering, DC removal, post-stage shaping amplification, peak detection, system self-test, phase shifting and driving circuit; The control module includes a single chip microcomputer, FPGA, clock, ADC, comparator and lookup table EEPROM; The magnetoelectric sensor includes an excitation coil and a detection coil; The excitation coil forms a spatially symmetrical reverse excitation electromagnetic field when a high-frequency current flows through it, and the total inductance of the excitation coil and the detection coil is about 110 μH; The FPGA provides various clock generation, clock phase shifting, and system self-test functions; The ADC converts the signal from the peak detection circuit into a numerical signal for processing by the single chip microcomputer; The single chip microcomputer is responsible for the control, management, communication, ADC data processing and external display of the entire system; The comparator is used to compare the signals of I and Q channels with the preset thresholds and output TTL pulses; The lookup table EEPROM is used to store system calibration data and calculate the relationship between peak detection voltage and particle size.

2. The aircraft engine oil wear particle online detection system according to claim 1, characterized in that: The chassis supports explosion-proof, EMI-proof and heat dissipation, and the connectors on the chassis all use military standards.

3. The aircraft engine oil wear particle online detection system according to claim 1, characterized in that: The excitation coil and the detection coil include lead wires, and the lead wires are all shielded wires.

4. The aircraft engine oil wear particle online detection system according to claim 1, characterized in that: The working environment of the aircraft engine oil wear particle online detection system is: Working altitude: -600~12600 meters Sensor operating temperature: -55~180℃ Signal processing unit working temperature: -55~125℃ Working environment pressure: 20~110kPa Working environment vibration: 10-50Hz: displacement is 3mm; 50-300Hz: acceleration is 15g.

5. The aircraft engine oil wear particle online detection system according to claim 1, characterized in that: The control module has one.

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