A transportable airborne power detection and service shelter
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- SHAANXI AVIATION ELECTRICAL
- Filing Date
- 2022-09-26
- Publication Date
- 2026-07-03
Smart Images
Figure CN115754505B_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of aviation power electrical product testing, specifically relating to a mobile aviation power supply testing and maintenance container. Background Technology
[0002] The aircraft generator testing equipment mainly consists of a drive unit, speed regulation and control device, aircraft generator cooling system, simulated load, product control console, product testing fixtures and related control consoles and mechanical-hydraulic interfaces. The power drive unit simulates the driving characteristics of the generator and serves as the power unit to drive it. It controls, protects, and monitors the transformer rectifier, motor, speed regulation device, cooling oil pump motor, fan, and other related test facilities configured in the aircraft generator drive unit. The aircraft generator cooling system consists of a pressure oil injection circuit for the generator under test and a cooling circulation circuit during normal operation. It controls and regulates the circulating oil temperature rise generated during generator operation through circuit heat exchange to ensure that the circulating oil temperature of the main generator under test remains within the permissible normal operating temperature range. The product testing fixture is used to connect and install the generator under test to the power drive unit to achieve power transmission. The simulated load is a load device that simulates the generator's load capacity, and the simulated load has the function of adding and unloading three-phase loads at any required load level. The control console is used for product data measurement and display, and for checking and controlling signal logic protection functions.
[0003] Testing of aviation electrical products is divided into open-loop testing and closed-loop testing. Open-loop testing uses a power supply to simulate generator power generation and simulates the output signal of a current transformer. The open-loop performance and protection functions of the controller are checked through the generator control unit, display and detection unit, and logic protection unit. Closed-loop testing uses a matching generator and controller to achieve closed-loop generator power generation through the generator control unit. Data and signals are acquired by the acquisition module, displayed and detected by a computer, and the control is checked through the logic protection unit.
[0004] Existing aviation power supply testing equipment, while meeting the testing requirements for aviation electrical products, is large in size, requires a lot of space for installation and use, is heavy, and is inconvenient to move. Furthermore, the testing equipment and instruments for aviation generators and electrical products are separate and independent, resulting in untimely field testing and maintenance of aviation generators and electrical products, and long repair cycles. The military does not yet have equipment that meets the current testing requirements, which affects the normal operation of aircraft. Summary of the Invention
[0005] The technical problem to be solved:
[0006] To overcome the shortcomings of existing technologies, this invention provides a mobile aviation power supply testing and maintenance container. Designed to ensure field testing, fault diagnosis, product repair, and experimental verification of products, it minimizes equipment size and weight. Internally, it integrates testing equipment required for aviation electrical and electronic product testing, fault diagnosis, repair, and post-repair verification. The volume and weight of the integrated equipment are reduced by more than half compared to conventional ground-based equipment. Employing a modular design, it integrates testing and repair functions for aviation generators and electrical products. Designed according to general standards, the container features insulation, waterproofing, fireproofing, and leakage prevention, facilitating transportation and offering high comprehensiveness and mobility. This container is used to address the testing, fault diagnosis, repair, and post-repair verification of aviation power supplies on-site, enabling comprehensive inspection and testing of aircraft electrical and motor products in the field, thus preventing product failures in the field. Through targeted pre-testing and LRU-level repair of field power system products, it effectively reduces the failure rate of field products, shortens maintenance cycles, ensures aircraft availability, and improves field service support capabilities.
[0007] The technical solution of the present invention is: a mobile aviation power supply testing and maintenance cabin, characterized in that: it includes a cabin body and an integrated drive device 1, a cooling device 2, a simulated load 17, a dynamic balancing machine 19, a motor product maintenance workbench 22, an electrical product maintenance workbench 8, a product testing unit 6, and a test fixture 3.
[0008] The drive unit 1 is used to drive the generator to provide the kinetic energy required for testing the aircraft generator;
[0009] The cooling device includes an oil injection system, a product oil circulation system, and a lubricating oil cooling system. The oil injection system supplies oil to the product oil circulation system, the product oil circulation system is used for product lubricating oil circulation, and the lubricating oil cooling system is used for cooling the lubricating oil.
[0010] The test fixture 3 is used to connect and install the generator under test with the drive device 1 to realize power transmission;
[0011] The simulated load 17 serves as a device for simulating the generator's load-carrying capacity.
[0012] The dynamic balancing machine 19 is used for dynamic balancing calibration of the rotor of motor products during repair.
[0013] The motor product repair workbench 22 is used for disassembling, inspecting, replacing components, and assembling aircraft generator products.
[0014] The electrical product repair workbench 8 is used for disassembling, inspecting, replacing parts, and assembling electrical products.
[0015] The product testing unit 6 is used for product testing and verification.
[0016] A further technical solution of the present invention is: the drive device 1 adopts a high-speed AC variable frequency motor with single-shaft output to drive the generator, and is equipped with a speed encoder to provide real-time speed signal; the high-speed AC variable frequency motor adopts AC variable frequency stepless speed regulation and can rotate in reverse; it is provided with an output end face stop and fixing screw hole to bear the suspension torque of the aircraft generator installation.
[0017] A further technical solution of the present invention is: the cooling device includes a dual-path system with the same structure for two different grades of oil, each path of which operates independently and can achieve the cooling function of the two products.
[0018] A further technical solution of the present invention is: one of the two systems in the dual-path system includes an oil injection system, a product oil circulation system, and a lubricating oil cooling system (shared);
[0019] The oil injection system shares the same oil injection pipeline and the product's circulating oil pipeline during operation. At the same time, a dual-shaft extension motor 2e drives two oil injection pumps 2d. By changing the rotation direction of motor 2e, oil is supplied to the two lubricating oil pipelines. The oil pumps 2d and motor 2e are connected by flanges. The oil suction port of oil pump 2d is connected to a stainless steel pipe by a threaded pipe fitting, and then connected to the first ball valve 2c to the oil tank through the threaded pipe fitting, so as to connect the oil pump and the oil suction pipeline.
[0020] The oil pump 2d's outlet is connected to a stainless steel pipe via a threaded fitting, and then connected to a stainless steel one-way valve 2a via the fitting. A stainless steel pipe and a tee fitting are used to connect to the first filter 2b. Similarly, a flow meter 2g is connected, and then a four-way fitting connects to the inlet pipe, inlet pressure sensor 2i, and inlet temperature sensor 2u. A tee fitting then connects the inlet pipe to the stainless steel pipe 2j and to the second ball valve 2k, providing an oil inlet for detection. A stainless steel hose 2l connects the oil supply port to the product inlet. After passing through the product, the lubricating oil is connected from the outlet to the circulation system outlet pipe via the stainless steel hose 2l, and then to the inlet pipe, return pressure sensor 2v, and return temperature sensor 2h via a four-way fitting. After passing through the heat exchanger 2o, the lubricating oil is recirculated through a one-way valve into the inlet pipe filter, achieving product lubricating oil circulation.
[0021] The lubricating oil pump 2s and oil pump 2t in the lubricating oil cooling system are connected by flanges. The suction filter 2r, the third ball valve 2q, the heat exchanger 2o, the second filter 2y, and the heat exchanger 2r are all connected by threaded pipe fittings and pipelines. The hydraulic components and pipelines are connected by stainless steel threaded pipe fittings. The lubricating oil is cooled by air and can move with the system.
[0022] A further technical solution of the present invention is as follows: the test fixture 3 is a common mounting plate 1b, which is a sleeve structure with flanges at both ends. One flange is fixedly connected to the output flange of the drive motor 1a by bolts arranged circumferentially, and the other end is connected to one end of the product mounting plate 1d by a common clamp 1c. The other end of the product mounting plate 1d is connected to the product under test by a product mounting clamp 1e. The output shaft of the drive motor 1a is connected to the product output shaft by a product coupling 1f to realize power transmission.
[0023] A further technical solution of the present invention is: the simulated load 17 is installed on the outer side of the cabin, including a shell and a resistor assembly and an electrical control board disposed therein, and the shell is waterproofed.
[0024] A further technical solution of the present invention is: the dynamic balancing machine 19 is connected to the bottom plate of the cabin through a leveling device and a shock absorber; before use, the dynamic balancing machine 19 is adjusted to the horizontal range of use, and at the same time the shock absorber is de-damped to ensure the normal operation of the dynamic balancing machine.
[0025] A further technical solution of the present invention is as follows: the tabletop of the motor product repair workbench 22 is designed as a single piece of stainless steel, and a railing is set around it to prevent oil and parts from spilling during the loading and unloading of the oil-cooled motor; an oil drain groove is opened on the tabletop, and an oil tank is set below the oil drain groove, with an oil level indicator and an oil drain valve on the oil tank; a lockable drawer is set below the tabletop, where commonly used repair tools are placed according to their shape and clearly labeled.
[0026] A further technical solution of the present invention is: the surface of the electrical product repair workbench 8 is covered with an insulating layer, and an electrostatic discharge ball is designed on the side, which is grounded to the cabin; three 3-hole 220V sockets are provided on the top of the electrical product repair workbench 8, and grounding screws are provided at the bottom; a lockable drawer is provided under the workbench surface, which is placed according to the shape of commonly used repair tools and clearly labeled.
[0027] A further technical solution of the present invention is as follows: the product testing unit 6 automatically selects and connects the corresponding power supply and test module according to the product testing requirements; the adjustment of the power supply is automatically completed by the electrical product testing unit; the entire testing process of the product is automatically completed on the electrical product automatic measurement and control system; the fault displayed by the product is located on the specific circuit board inside the product; the computer testing software of the product testing unit 6 is designed according to functional modules, and each tested product corresponds to its own independent test module.
[0028] Beneficial effects
[0029] The beneficial effects of this invention are as follows: This mobile aviation power dynamic testing and maintenance container is highly comprehensive and mobile, enabling on-site testing, fault diagnosis, product repair, and testing of aviation electrical products at the user's location. This reduces the time for product testing, troubleshooting, and repair for military users from the original 20-30 days to 2-3 days, effectively lowering the failure rate of on-site products, shortening maintenance cycles, ensuring aircraft availability, and greatly improving the service support capabilities and efficiency for military users.
[0030] The electrical product testing equipment of this invention employs a computer-controlled system to automatically complete product testing. It utilizes a shared programmable power supply, reducing the number of power sources and minimizing equipment size and weight. The product testing and verification unit is designed as a drawer module for easy installation and fixation within the container. The drive unit uses a high-speed variable frequency motor as the power source for direct drive, which, compared to conventional drive units, reduces gearbox components and lubrication systems, significantly reducing the size and weight of the drive unit. Instruments, tooling, and fixtures used during testing and maintenance are all stored in dedicated drawers, securely fixed within marked drawers with lockable rails. The container integrates aviation generators and electrical product testing equipment and instruments, enabling the testing and maintenance of aviation electrical products to be completed entirely within the container.
[0031] The testing and verification module for electrical products is designed as a computer-automated testing software module. Each product model has its own independent testing module, which is easy to operate. The entire testing process for electrical products is automatically completed on the computer-controlled testing system, and the fault can be located to the specific circuit board of the product based on the fault displayed by the product. Automated testing and control improves the efficiency of product testing, and product fault location can pinpoint the circuit board with the internal fault, shortening the fault diagnosis, location, and time, which is at least twice as efficient as manual operation.
[0032] The mobile aviation power dynamic testing and maintenance container is equipped with various disassembly and assembly tooling, testing instruments, special and general tools for maintenance of aviation electrical products, spare electrical product printed circuit board assemblies and auxiliary materials. Inside the container, products can be tested and fault located, repaired, and post-repair verification tests can be carried out. After completion, it can be delivered to military users in a timely manner, improving the timeliness of service support.
[0033] The mobile aviation power dynamic testing and maintenance cabin can conduct general inspections and tests on aircraft electrical products and motor products in the field, which can prevent product failures in the field.
[0034] The mobile aviation power dynamic testing and maintenance cabin can be gradually extended to the field testing and maintenance of power system supporting products for other aircraft models.
[0035] From October 10 to November 13, 2021, support work was carried out for the field trial of the mobile aviation power supply dynamic testing and maintenance container. The testing of 7 types of products, including motors and electrical appliances, was completed, and the container was verified to meet the usage requirements.
[0036] From February 21 to April 1, 2022, the mobile testing facility conducted on-site testing and support for supporting power supply products. It completed the testing of 9 types of products, including motors and electrical appliances. The mobile testing facility was used to conduct a comprehensive survey of these 9 types of products, achieving the expected goal of early problem detection and providing good support services. The results were remarkable, ensuring the quality and safety of the onboard power system, strengthening the quality foundation of the aircraft, and receiving positive feedback from the troops.
[0037] A "Mobile Aviation Power Supply Dynamic Testing and Maintenance Container" possesses the capability to test and diagnose faults in a certain type of onboard power supply product, enabling product testing, fault diagnosis, repair, and post-repair verification. Designed according to general standards, it is easy to transport by vehicle and boasts high comprehensiveness and mobility. The container achieves the goals of reducing the failure rate of field products, shortening maintenance cycles, ensuring aircraft uptime, and improving rapid field service support capabilities. It provides assurance for the means and capabilities of field technical services for aviation power supplies and provides effective support for the normal operation of aircraft. Attached Figure Description
[0038] Figure 1 Left side view of a mobile aircraft power supply testing and maintenance container;
[0039] Figure 2 External right side view of a mobile aircraft power supply testing and maintenance container;
[0040] Figure 3 Front view of a mobile aircraft power supply testing and maintenance container;
[0041] Figure 4 Rear view of a mobile aircraft power supply testing and maintenance container;
[0042] Figure 5 Left side view of a mobile aircraft power supply testing and maintenance container;
[0043] Figure 6 Rear view of a mobile aircraft power supply testing and maintenance container;
[0044] Figure 7 Right side view of a mobile aircraft power supply testing and maintenance container;
[0045] Figure 8 Floor plan of a mobile aircraft power supply testing and maintenance container;
[0046] Figure 9 A front view of the interior of a mobile aircraft power supply testing and maintenance container;
[0047] Figure 10 A diagram of the drive unit components for a mobile aircraft power supply testing and maintenance container;
[0048] Figure 11 A diagram of a portable aircraft power supply testing and maintenance container - cooling unit components;
[0049] Figure 12 A mobile aviation power supply testing and maintenance cabin - diagram of testing power supply and product testing and verification components;
[0050] Explanation of reference numerals in the attached drawings: 1. Drive unit, 2. Cooling unit, 3. Test fixture, 4. Distribution cabinet, 5. Test power supply, 6. Product testing and verification, 7. Hanging cabinet, 8. Electrical repair workbench, 9. Hanging cabinet, 10. Folding chair, 11. Hand-held air compressor, 12. Power socket, 13. Shock absorber, 14. Manual crane (for testing), 15. Manual crane (for repair), 16. Heating and cooling air conditioner, 17. Simulated load, 18. Cable tray, 19. Dynamic balancing machine, 20. Leveling and fixing device, 21. Fixture storage cabinet, 22. Motor repair workbench, 23. Equipment storage cabinet, 24. Hanging cabinet, 25. Oven, 26. Grounding stake, 27. Dry powder fire extinguisher, 28. Cabinet, 29. Power cord reel;
[0051] High-speed motor 1a, common mounting plate 1b, product testing fixture 1c;
[0052] Stainless steel check valve 2a, filter 2b, first ball valve 2c, first oil pump 2d, motor 2e, check valve 2f, flow meter 2g, platinum resistance thermometer 2h, pressure sensor 2i, oil pipe 2j, second ball valve 2k, hose 2l, pressure sensor 2m, hose 2n, radiator 2o, heat exchanger 2p, third ball valve 2q, filter 2r, motor 2s, oil pump 2t;
[0053] Load control unit box 5a, detection power supply 5b, generator tester 5c, signal box 5d, industrial control computer 5e, keyboard 5f, closed-loop test unit box 5g, detection power supply 5h, power supply 5k, power supply 5m, power supply 5n, product test unit box 6a, signal box 6b, industrial control computer 6c, signal generator 6d, product test unit box 6e. Detailed Implementation
[0054] The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the invention, and should not be construed as limiting the invention.
[0055] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.
[0056] This invention discloses a mobile dynamic testing and maintenance container for aviation power supplies. Four lifting mechanisms are installed at its four corners to facilitate loading, unloading, and transfer without the need for cranes. A hoisting device is also included, expanding the container's mobility and site adaptability. This container achieves comprehensive testing capabilities for aviation electrical products. Its ease of loading, unloading, and transfer makes it particularly suitable for field testing and maintenance of aviation electrical products, solving problems such as delayed response and long repair cycles. It effectively reduces the failure rate of field products, shortens maintenance cycles, ensures aircraft availability, and enhances field service support capabilities.
[0057] Reference Figure 1-9 As shown, the mobile aviation power dynamic testing and maintenance cabin of the present invention adopts a functional modular design. The main equipment and devices integrated inside include a drive device 1, a cooling device 2, a simulated load 17, a dynamic balancing machine 19, a motor product maintenance workbench 22, an electrical product maintenance workbench 8, a product testing unit 6, and a test fixture 3.
[0058] Drive unit 1 is the power unit used to drive the generator, providing the kinetic energy required for testing the aircraft generator. The drive unit uses a high-speed AC variable frequency motor with single-shaft output to drive the generator, and is equipped with a speed encoder to provide real-time speed signals. The high-speed AC variable frequency motor is specially designed to meet the output power, speed range (constant torque, constant power), and maximum output speed requirements for the testing and maintenance of the aircraft generator in the container. It features single-shaft output and reversible direction; the speed regulation method is AC variable frequency stepless speed regulation; it can operate stably for a long time, and also has an output end face stop and fixing screw holes to bear the suspension torque of the aircraft generator installation.
[0059] Reference Figure 11As shown, the cooling device 2 consists of an oil injection system, a product oil circulation system, and a lubricating oil cooling system. The oil injection circuit, comprising an oil tank, oil pump motor, check valve, oil filter, pressure regulator, pressure sensor, and piping, is used to inject oil into the generator under test. The product oil circulation system, consisting of a pressure sensor, temperature sensor, flow sensor, oil filter, heat exchanger, and connecting piping, and the lubricating oil cooling circulation circuit, consisting of a temperature sensor, oil filter, heat exchanger, and connecting piping, is used to control and regulate the lubricating oil temperature rise generated during generator operation, ensuring that the lubricating oil temperature of the generator under test remains within the permissible normal operating temperature range through circuit heat exchange. The oil injection system is used to inject a certain amount of lubricating oil into the generator under test before operation; the product oil circulation system, powered by the product itself, provides lubricating oil temperature, flow rate, and pressure detection, as well as lubricating oil filtration during generator operation; the lubricating oil cooling system regulates the lubricating oil temperature during product oil circulation system operation. The aircraft generator cooling device provides cooling lubricating oil for liquid-cooled aircraft generators, ensuring adequate cooling lubricating oil for generator operation. This cooling unit features dual-channel oil filling and dual-channel cooling, catering to two different grades of oil. Each channel operates independently, providing cooling for both products. The base plate is equipped with an oil collection tray and mounting holes, and is secured to the container. The oil filling system, product oil circulation system, and lubricating oil cooling system are all integrated within the base of the vehicle's drive unit. An oil collection tray at the bottom facilitates cleaning of the chassis when oil accumulates. The lubricating oil cooling structures for both types of liquid-cooled aircraft generators are identical, but they use different grades of lubricating oil and have two independent lubricating oil lines. This description focuses on one type of lubricating oil line. According to the requirements for use of aircraft generators, the product must be filled with oil before use. In order to reduce the size of the device and save space, the product's oil filling pipeline and the oil circulation pipeline during operation are shared. At the same time, a dual-shaft extension motor 2e drives two oil pumps 2d. By changing the rotation direction of motor 2e, oil is supplied to the two lubricating oil pipelines. The oil pump 2d and motor 2e are connected by flanges. The oil suction port of oil pump 2d is connected to a 16-inch stainless steel pipe by a self-designed and manufactured threaded pipe fitting. Then, the threaded pipe fitting is used to connect to the stainless steel one-way valve 2c (set up for easy maintenance and repair) to the oil tank to connect the oil pump's oil suction pipeline.The oil pump 2d's outlet is connected to a 16mm inner diameter stainless steel pipe via a threaded fitting, and then connected to a stainless steel check valve 2a via a fitting. A stainless steel pipe and a tee fitting connect to the filter 2b. A flow meter 2g is connected in the same way. A four-way fitting connects the inlet oil line, inlet pressure sensor 2i, and inlet temperature sensor 2u. A tee fitting connects the inlet oil line and stainless steel pipe 2j (6mm inner diameter) to ball valve 2k, providing an oil inlet for detection. A stainless steel hose 2l (16mm inner diameter) connects the oil supply port to the product inlet. After passing through the product, the lubricating oil is connected from the outlet to the circulation system outlet line via the stainless steel hose 2l. A four-way fitting connects the inlet oil line, return oil pressure sensor 2v, and return oil temperature sensor 2h. After passing through the heat exchanger, the lubricating oil is recirculated through a check valve into the inlet oil filter, achieving product lubricating oil circulation. The lubricating oil cooling system consists of a lubricating oil pump 2s and a drive motor 2t connected by flanges, and threaded pipe fittings for the suction filter 2r, ball valve 2q, heat exchanger 2o, filter 2y, and heat exchanger 2r. Stainless steel threaded fittings are used to connect the hydraulic components and pipes. Lubricating oil is cooled by air and the system is movable.
[0060] Reference Figure 10 As shown, the product testing fixture 3 is used to connect and install the generator under test with the drive device 1 to achieve power transmission. The product testing fixture is designed as a common mounting plate 1b installed on the output shaft end face of the drive motor 1a. One end of the common mounting plate 1b is fixed to the output end of the drive motor 1a with screws, and the other end is connected to one end of the product mounting plate 1d with a quick-release common clamp 1c. The other end of the product mounting plate 1d is connected to the product under test with a quick-release product mounting clamp 1e. Power transmission is achieved by connecting the output shaft of the drive motor 1a and the output shaft of the product using a product coupling 1f.
[0061] The simulated load 17 is a simulated load device for the generator's load-carrying capacity. The simulated load has the function of adding and unloading three-phase loads at any required load level. This simulated load is a self-designed and manufactured, waterproof and rainproof suspended power load box, installed and fixed on the end face of the container. Protective side plates and a bottom plate are designed around the resistor components and electrical control board, sealed with rubber gaskets to prevent rainwater ingress. The bottom plate has drainage outlets for waterproofing. The resistor elements are manufactured using high-temperature resistant, high-resistivity materials and self-made tooling, ensuring long-term stable operation.
[0062] The dynamic balancing machine 19 is used for rotor dynamic balancing calibration in motor product repair. A leveling device for the dynamic balancing machine is designed inside the cabin. The dynamic balancing machine is installed on the leveling device, which is connected to the cabin floor through a shock absorber. Before use, the dynamic balancing machine is leveled to the operating range by a mechanism, while the shock absorber is de-damped to ensure the normal operation of the dynamic balancing machine.
[0063] The motor repair workbench 22 is used for disassembling, inspecting, replacing parts, and assembling aircraft generators. The workbench features a one-piece stainless steel tabletop with approximately 50mm high railings around the perimeter to prevent oil and parts from spilling during the handling of oil-cooled motors. An oil drain pan is designed on the tabletop, with an oil tank underneath. The oil tank includes an oil level indicator and a drain valve. The workbench also has lockable drawers for storing commonly used repair tools, clearly labeled.
[0064] The electrical product repair workbench 8 is used for disassembling, inspecting, replacing components, and assembling electrical products. The workbench surface is covered with an insulating layer, and the sides are designed with electrostatic discharge balls connected to the grounding of the control room. Three 220V three-hole sockets are located above the workbench, and the workbench is equipped with grounding screws. The workbench has lockable drawers, where commonly used repair tools are arranged according to their type and clearly labeled.
[0065] Product testing unit 6 is used for product testing and verification. It comprises product testing and verification, power supply cabinet 5, drive unit 1, cooling unit 2, test fixture 3, and simulated load 17. During product testing, it needs to be connected to the corresponding test module inside the testing unit. The testing program automatically selects the appropriate power supply and connects it to the test module according to the product testing requirements. Power supply adjustment is automatically completed by the electrical product testing unit. The entire product testing process is automatically completed on the electrical product automatic measurement and control system, which can locate the specific circuit board within the product based on the fault displayed. The computer testing software is designed according to functional modules, with each tested product corresponding to its own independent test module.
[0066] Aviation electrical product testing is divided into open-loop testing and closed-loop testing. Open-loop testing uses a power supply to simulate generator output and transformer output signals. The open-loop performance and protection functions of the controller are checked through the generator control unit, display and detection unit, and logic protection unit. Closed-loop testing uses a matching generator and controller to achieve closed-loop generator output through the generator control unit. Data and signals are acquired by the acquisition module, displayed and detected by a computer, and the control is checked through the logic protection unit.
[0067] 1. Transfer and installation
[0068] For easy loading and unloading, a foldable lifting mechanism is provided. The mechanism is simple and convenient to operate, and has a stop function at any working state during the lifting and lowering of the container. The lifting process is smooth and reliable, and has a self-locking function. It facilitates loading, unloading, and transportation. After the container is transported to the test site, the leveling mechanisms at the four corners of the container are adjusted, and the container level is observed to ensure that the entire container is level.
[0069] 2. Power on the device
[0070] First, check that the control devices inside the shelter are securely installed and not loose. Use a power cable reel to quickly connect one end of the 29 cable (waterproof plug) to the inlet socket of the shelter's junction box, and the other end (lug) to connect to the power distribution cabinet at the site. Turn on the power distribution cabinet switch, and then turn on the corresponding power switch according to the shelter's usage conditions. The shelter is now powered on.
[0071] 3 Product Testing
[0072] Product testing unit 6 can automatically complete the prescribed tests with one click according to the product model, or select test items for testing. It consists of a motor product testing system and an electrical product testing system. The motor product testing system can control the generator speed and generator oil circuit system to perform closed-loop power generation function testing. The electrical product testing system can perform open-loop testing of electrical products.
[0073] 3.1 Testing of motor products
[0074] Entering the system: After booting up and entering the running interface, you must first log in to the system before you can perform related tests. After entering the user management interface, enter the correct username and password, and the current user can then operate the system.
[0075] System self-test: After pressing the "System Self-test" button on the left side of the main interface, you will enter the analog channel self-test interface. You can observe the voltage value acquired by the current analog channel in real time. When the analog acquisition is abnormal, you can check whether the current analog channel is working properly through this interface, which will help you to further determine the fault location.
[0076] Product Testing: After pressing the "Product Test" button on the left side of the main interface, you will enter the product testing interface. Product testing is divided into different areas. The cooling device display area shows the temperature, pressure, and flow rates during generator testing. The cooling temperature, pressure, and flow rate have been set according to different product test requirements, and product testing unit 6 automatically adjusts its operation based on these settings. The generator parameter display area shows relevant data during generator testing, including real-time data for main generator voltage, main generator current, DC current, and DC voltage.
[0077] Based on the model of the generator under test, retrieve the corresponding product test fixture from fixture placement cabinet 21, install it on the output interface of drive unit 1, connect the oil lines, and connect the A, B, C, and N main lines to the corresponding output terminals of the generator, confirming that the corresponding phase sequence is consistent. Connect the corresponding generator signal cable plug to the generator signal socket. Connect the corresponding controller product cable to the detection socket of the corresponding test unit on the closed-loop test unit box (note that only one product can be connected to the corresponding test unit at a time). Detect the generator's output voltage, current, excitation current values, and their waveforms, and transmit the generator's voltage and current values to the drive computer for unified display and storage.
[0078] In the drive control area, when testing the product, the first step is to determine the product's rotation direction (this is very important). If you need to change the rotation direction, you must first enter the direction selection password. After entering the correct password, press the "Motor Forward / Reverse Selection" button to switch the current motor rotation direction. After pressing the "Drive Contactor Control" button, the drive inverter will be powered on. After setting the motor speed according to the test requirements, press the "Drive Motor Start" button to start the drive inverter, and press the "Drive Motor Stop" button to stop the drive inverter.
[0079] Select the product model on the computer measurement and control interface to enter the corresponding product test interface; connect the three-phase voltage, current and excitation current signals on the generator tester signal interface board to the voltage and current ports of the tester, and turn on the generator tester to enable normal communication between the tester and the test interface.
[0080] On the control interface, turn on the power to the oil injection frequency converter, adjust the oil injection pump speed, and observe that the product oil level reaches the calibrated oil level. Then, stop the oil injection frequency converter and disconnect its power. On the control interface, turn on the power to the cooling frequency converter to power on the cooling pump frequency converter; on the control interface, turn on the power to the cooling radiator to start the cooling radiator.
[0081] Start the drive inverter on the control interface and adjust the input speed and oil inlet temperature. Conduct the test according to the product test procedure. The drive computer detects the generator speed, permanent magnet voltage, excitation voltage, excitation current and load, as well as the temperature, pressure and flow rate of the generator cooling system. The detected data can be transmitted to the drive computer for unified display and storage.
[0082] The generator tester can display the main generator voltage waveform, current waveform, excitation voltage waveform, and excitation current waveform to analyze the generator's power generation status.
[0083] After the generator test is completed, disconnect the generator load, the generator stops generating electricity, but the generator does not stop rotating. Adjust the cooling pump speed to reduce the product oil temperature to the specified value. After stopping the drive, press the emergency stop button to de-energize the drive inverter, then disconnect the cooling inverter and disassemble the generator product.
[0084] 3.2 Testing and Verification of Electrical Appliances
[0085] Connect the test product to the corresponding test unit's test socket using the product cable (note that only one product can be connected to the corresponding test unit at a time). Turn on the power switch on the power cabinet's adapter box to power on the power cabinet.
[0086] Start the product testing computer, open the product testing software, select the product to be tested, and enter the corresponding product's testing interface to conduct the experiment.
[0087] Open-loop testing: After powering on and entering the operating interface, you must log in to the system before you can perform related tests. You cannot operate any functions while logged out or not logged in. After entering the main system interface, first click "User Management" to select a username and password to log in. The currently logged-in username will be displayed in the upper right corner of the interface. After entering the user management interface, enter the correct username and password, and the current user can then operate the system. The username will be displayed in the upper right corner of the main interface.
[0088] System self-test: After pressing the "System Self-test" button on the left side of the main interface, you will enter the analog channel self-test interface. In this interface, you can observe the voltage value acquired by the current analog channel in real time. When the analog acquisition is abnormal, you can check whether the current analog channel is working properly through this interface, which will help you to further determine the location of the fault.
[0089] Sensor Measurement Interface: After pressing the "Sensor Measurement" button on the left side of the main interface, you will enter the analog quantity acquisition channel calibration interface, through which users can calibrate the analog quantities used in the system.
[0090] Product selection interface: After entering the product selection interface, press the "Product Model" button to enter the product testing interface.
[0091] In the product testing interface, select the product type in the product signal box, enter the relevant information in the other information boxes, and you will be automatically taken to the corresponding product testing page.
[0092] On the product testing page, if the test type is set to automatic, clicking the "Start Test" button will automatically complete all test items according to the product testing process and automatically save the test results. If an interruption is needed during the automatic test, press "Pause" to stop the test, and then click the "Start" button again to resume the test from the breakpoint until the test ends.
[0093] If you select single-step as the test type, a product test item list box will pop up. You can select a test item in the list box and click the test start button to start the test process for that item. The test will stop automatically after it is completed.
[0094] Product Testing: The product testing interface can be divided into 5 areas. Area 1 displays the current test step, such as switch closing or voltage adjustment. Area 2 is the switch operation area; the switches in this area close according to the test requirements, and the current status after the switch action is displayed in Area 1. Area 3 allows adjustment of the three power supplies. Area 4 displays the current power supply voltage and frequency; the displayed values are only shown after the power supply voltage or frequency has been set. Area 5 is used to select the starting test item for automatic testing. After selecting the starting test item, pressing the automatic run button will start the test from the selected starting item until the test ends.
[0095] For specific manual testing procedures, please refer to the testing procedures for each electrical product.
[0096] 4. Maintenance and upkeep
[0097] The equipment should be managed by designated personnel who should regularly monitor its operation.
[0098] Regular daily cleaning and tidying are essential to ensure the cleanliness of the test bench and the area around it, in order to maintain optimal equipment performance.
[0099] Dust should be regularly removed from the equipment surface and pipelines, and leaks should be repaired promptly.
[0100] According to the system schematic diagram, all connections should be secure and without any looseness, and the cabinet should be kept clean and free of foreign objects.
[0101] Regularly check the continuity of all operating switches and electrical components, and replace any switches or electrical components with poor contact in a timely manner.
[0102] To ensure the accuracy of measurement data, the sensors used in the system should be calibrated regularly, and sensors that cannot be calibrated should be replaced in a timely manner.
[0103] Regularly check whether the fasteners of the equipment are loose. If any are loose, tighten them in time to eliminate equipment vibration and pipeline leakage caused by vibration.
[0104] Pay attention to any abnormal sounds during operation. If any abnormalities are found, stop the machine immediately and check it.
[0105] Pay attention to the oil level in the lubrication system's oil tank. If the oil level is less than half of the standard oil level, add oil promptly.
[0106] Establish maintenance and replacement records for the equipment and record them in a fixed record sheet so that they can serve as the basis for future maintenance.
[0107] The equipment should be maintained regularly, generally by changing the lubricating oil once a year, cleaning the system pipelines and hydraulic components, ensuring the unobstructed flow of the system pipelines, and ensuring the long-term, normal and stable operation of the equipment.
[0108] This equipment contains electronic testing devices. If it is not used for a long period of time, it is necessary to power on the equipment for 1 hour periodically to prevent malfunctions.
[0109] Maintenance of the cabin should include regularly checking all rotating hinges for any issues such as stiffness or jamming, and applying lubricant to rotating parts as needed. Protect the exterior paint of the cabin; if any bumps or scratches occur, treat the surface immediately to prevent rust. Keep the interior clean and avoid water stains, as these can affect the operation of electrical equipment.
[0110] Precautions for operating the cabin lifting mechanism:
[0111] 1) When raising or lowering, the base must be properly placed and the ground must be level.
[0112] 2) Before operation, it must be confirmed that the connection between the mechanism and the container is secure and reliable, and that the limiting device is reliably positioned;
[0113] 3) The lifting and lowering must be synchronized, and the four legs must be kept at the same horizontal height as much as possible;
[0114] 4) Overtravel operation is strictly prohibited; pay attention to the scale indications;
[0115] 5) During loading and unloading, it is strictly forbidden for the vehicle to collide with the lifting mechanism and the container;
[0116] 6) Before driving, ensure that the lifting mechanism is retracted into place and securely fixed;
[0117] 7) It is strictly forbidden to disassemble or inspect the lifting mechanism under load;
[0118] 8) Please read the instruction manual carefully before operation.
[0119] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention.
Claims
1. A transportable airborne power detection and service shelter, characterized by: Includes the cabin and the integrated drive unit (1), cooling unit (2), simulated load (17), dynamic balancing machine (19), motor product repair workbench (22), electrical product repair workbench (8), product testing unit (6), and test fixture (3). The drive unit (1) is used to drive the generator to provide the kinetic energy required for testing the aircraft generator; The cooling device (2) includes an oil injection system, a product oil circulation system, and a lubricating oil cooling system. The oil injection system supplies oil to the product oil circulation system, the product oil circulation system is used for product lubricating oil circulation, and the lubricating oil cooling system is used for cooling the lubricating oil. The test fixture (3) is used to connect and install the generator under test with the drive device (1) to realize power transmission; The simulated load (17) serves as a device for simulating the generator's load-carrying capacity; The dynamic balancing machine (19) is used for dynamic balancing calibration of the rotor of motor products during repair. The motor product repair workbench (22) is used for the disassembly, inspection, replacement of parts and assembly of aircraft generator products; The electrical product repair workbench (8) is used for the disassembly, inspection, replacement of parts and assembly of electrical products; The product testing unit (6) is used for product testing and verification; The drive device (1) uses a high-speed AC variable frequency motor to drive the generator with a single shaft output, and is equipped with a speed encoder to provide real-time speed signal; the high-speed AC variable frequency motor adopts AC variable frequency stepless speed regulation and can rotate in reverse; it is equipped with an output end face stop and fixing screw hole to bear the suspension torque of the aircraft generator installation. The cooling device (2) includes a dual-path system with the same structure, used for two different grades of oil. Each path system operates independently and can achieve the cooling function of the two products.
2. The mobile aviation power supply testing and maintenance container according to claim 1, characterized in that: One of the two-path systems includes an oil injection system, a product oil circulation system, and a lubricating oil cooling system.
3. The mobile aviation power supply testing and maintenance container according to claim 1, characterized in that: The test fixture (3) is a common mounting plate (1b), which is a sleeve structure with flanges at both ends. One flange is fixedly connected to the output flange of the drive motor (1a) by bolts arranged along the circumference. The other end is connected to one end of the product mounting plate (1d) by a common clamp (1c). The other end of the product mounting plate (1d) is connected to the product under test by a product mounting clamp (1e). The output shaft of the drive motor (1a) is connected to the product output shaft through a product coupling (1f) to realize power transmission.
4. The mobile aviation power supply testing and maintenance container according to claim 1, characterized in that: The simulated load (17) is installed on the outer side of the cabin and includes a housing and a resistor assembly and an electrical control board disposed therein. The housing is waterproofed.
5. The mobile aviation power supply testing and maintenance container according to claim 1, characterized in that: The dynamic balancing machine (19) is connected to the bottom plate of the cabin through a leveling device and a shock absorber. Before use, the dynamic balancing machine (19) is adjusted to the horizontal range of use, and the shock absorber is made to lose its damping function to ensure that the dynamic balancing machine works normally.
6. The mobile aviation power supply testing and maintenance container according to claim 1, characterized in that: The workbench (22) for motor product repair is made of stainless steel and is surrounded by railings to prevent oil and parts from spilling during the loading and unloading of oil-cooled motors. There is an oil drain groove on the workbench and an oil tank below the oil drain groove. The oil tank is equipped with an oil level indicator and an oil drain valve. There is a lockable drawer under the workbench, which is used to store common repair tools and is clearly labeled.
7. The mobile aviation power supply testing and maintenance container according to claim 1, characterized in that: The surface of the electrical product repair workbench (8) is covered with an insulating layer, and the side is designed with an electrostatic discharge ball, which is connected to the ground of the cabin. There are three 3-hole 220V sockets on the top of the electrical product repair workbench (8), and a grounding screw is provided at the bottom. There is a lockable drawer under the workbench, which is placed according to the shape of commonly used repair tools and clearly marked.
8. The mobile aviation power supply testing and maintenance container according to claim 1, characterized in that: The product testing unit (6) automatically selects and connects the corresponding power supply and test module according to the product testing needs; the power supply is automatically adjusted by the electrical product testing unit; the entire product testing process is automatically completed on the electrical product automatic measurement and control system; the fault displayed by the product is located on the specific circuit board inside the product; the computer testing software of the product testing unit (6) is designed according to functional modules, and each tested product corresponds to its own independent test module.