A portable aircraft generator life testing device

Abstract

This invention provides a portable aircraft generator life testing device, comprising an internal resistance testing module, an electrode testing module, an audio testing module, and a power testing module, all connected to a main controller. These modules are external, plugged into the main unit of the testing device via connectors. This design enhances portability during testing, allowing for individual testing of each component or simultaneous testing of all components, offering greater flexibility. During testing, all aspects of the generator are measured simultaneously. The main controller performs comprehensive analysis and calculations based on the data from the internal resistance, electrode, audio, and power testing modules to obtain the aircraft generator life index F. The remaining lifespan of the aircraft generator is then calculated based on this index F. This comprehensive approach covers all factors affecting generator lifespan, resulting in more thorough and accurate testing.

Description

Technical Field

[0001] This invention relates to the field of aviation testing, and more specifically to a portable aircraft generator life testing device. Background Technology

[0002] Aircraft generators are divided into two main categories: DC and AC, and their working principle is the same as that of industrial motors. The main characteristics of aircraft generators are: they operate in harsh environments such as high altitude, high speed, and impact; they are driven by aircraft engines with a wide range of speed variations (2:1); and they use more efficient cooling systems and high-quality materials to reduce the weight-to-power ratio.

[0003] Due to the harsh working environment, strict maintenance must be carried out during the inspection to ensure that no problems occur. Otherwise, if any abnormality occurs during operation, it may affect the operation of the flight equipment or even lead to a major accident.

[0004] The current application number CN201110088594.2 discloses a portable aircraft generator life tester, including a core microprocessor system and a sensor system connected to the core microprocessor system, an A / D analog-to-digital conversion system, a large-capacity storage system, a power supply system, and a display and alarm system. However, its test items are insufficient, the test is not comprehensive, and the accuracy needs to be further improved. Summary of the Invention

[0005] To address the aforementioned problems, the present invention provides a portable aircraft generator life testing device, comprising a main unit, which includes an input module, a display unit, a main controller, a memory, and an analysis module; It also features an internal resistance detection module, an electrode detection module, an audio detection module, and a power detection module; The input module, display unit, memory, and analysis module are all connected to the main controller; the internal resistance detection module, electrode detection module, audio detection module, and power detection module are also connected to the main controller. The internal resistance detection module is used to detect the internal resistance of the internal windings of the aircraft generator; the electrode detection module is used to detect the corrosion rate of the wiring electrodes of the aircraft generator; the audio detection module detects the sound when the aircraft generator is working; and the power detection module detects the generating voltage and output current of the aircraft generator when it is working. The internal resistance detection module, electrode detection module, audio detection module, and power detection module are all external modules, which are plugged into the main unit of the detection device through the plug-in hole; The main controller performs comprehensive analysis and calculation on the data detected by the internal resistance detection module, electrode detection module, audio detection module and power detection module to obtain the life index F of the aircraft generator; and calculates the remaining life of the aircraft generator based on the life index F.

[0006] The main unit includes an upper housing 1, a lower housing 2, a circuit board 3, a wire insertion hole assembly 4, an input module 5, a battery 6, a back clip 7, a display unit 8, and a shielding cover 9; The circuit board, battery, and shielding cover are housed inside the space formed by the upper and lower housings; the wiring hole assembly protrudes through the upper housing; the shielding cover is located at the bottom of the wiring hole assembly; the back clip is located on the outside of the lower housing; the display unit and input module are located on the outer surface of the upper housing; the display unit is a display screen, and the input module is an input keyboard.

[0007] The internal resistance detection module is equipped with a temperature sensor and a resistance detector; the temperature sensor detects the winding temperature of the aircraft generator in real time, and the resistance detector detects the change in resistance of the winding as the temperature changes; thereby generating a resistance-temperature curve, and further obtaining the resistance-temperature function B(T). The internal resistance detection module sends the resistance-temperature function B(T) to the main controller; the main controller stores it in its memory. The analysis module processes B(T) and differentiates it to obtain B'(T); it then differentiates B'(T) again to obtain B''(T); and calculates T1 corresponding to the maximum value and T2 corresponding to the minimum value of B''(T).

[0008] The electrode detection module is equipped with a corrosion rate detector. The electrode corrosion rate is measured using an image method, that is, the corrosion rate detector takes an image of the electrode position and sends the image to the main controller; the main controller obtains the electrode corrosion rate L after preprocessing the image. The corrosion rate detector is equipped with a standard color block. During the test, the standard color block is placed near the electrode, and the standard color block and the electrode are captured in one image to obtain the test image. The memory stores the standard values ​​of the RGB channels of the standard color blocks; the RGB channels of the detection image are adjusted to make the RGB values ​​of the standard color blocks in the detection image equal to the standard values, thereby achieving color calibration; After color calibration, the detection image is segmented to separate the electrode region from the detection image and process it separately to obtain a segmented electrode image. The main controller extracts the R values ​​of all pixels in the segmented electrode image and obtains the maximum value R1 of the R channel. Then, it extracts the region where the R value of all pixels exceeds 80% of R1 to obtain the pixels of the eroded region. It calculates the proportion P of the number of pixels in the extracted eroded region to the total number of pixels in the segmented electrode image and obtains the erosion rate L through the mapping relationship between P and L.

[0009] The audio detection module includes an audio acquisition unit, i.e., a microphone, which collects the sound of the aircraft generator when it is working, and divides the collected audio into 5-second segments, sending the audio segments to the main controller. At least 10 audio segments were collected, with a time interval of at least 5 seconds between each segment. The main controller processes the audio segment to obtain the average spectrum of the audio segment; and compares the average spectrum with the audio spectrum of the aircraft generator in a healthy state to calculate the similarity H. The main controller calculates the average similarity H0 of all audio segments and defines the audio risk coefficient R = 1 - H0.

[0010] The power detection module includes a voltage and current recorder, which detects the output voltage and current of the aircraft generator in real time and obtains voltage-time curves and current-time curves, and further obtains voltage-time function U(t) and current-time function I(t); The power detection module sends the voltage-time function U(t) and the current-time function I(t) to the main controller; The main controller calculates the standard deviation δ1 of the voltage-time function U(t) over a 1-minute time period and the standard deviation δ2 of the current-time function I(t) over a 1-minute time period.

[0011] The main controller stores the following data in its memory: the resistance-temperature function B(T) and B''(T) with maximum values ​​corresponding to T1 and minimum values ​​corresponding to T2, the electrode corrosion rate L, the audio risk coefficient R, the voltage-time function U(t), and the current-time function I(t).

[0012] The analysis module calculates the life index of the aircraft generator: F=F0-k1·[B(T1) / B(T2)]-k2·L- k3·R-k4·δ1-k5·δ2; F0 is the original maximum lifespan index; k1 to k5 are coefficients, which also represent the weights of each parameter. k1 to k3 are dimensionless values, k4 is in units of 1 / V, and k5 is in units of 1 / A. The analysis module also solves for Y based on the one-to-one correspondence between the aircraft generator life index F and the aircraft generator remaining life Y.

[0013] The one-to-one correspondence between the life index F of the aircraft generator and the remaining life Y of the aircraft generator is constructed as follows: the life index F of multiple brand-new aircraft generators is detected from the moment they are brand new and they are continuously operated until the aircraft generator is damaged and the remaining life is 0; the one-to-one correspondence between the detected life index F of the aircraft generator and the remaining life Y of the aircraft generator is established throughout the test process. The mapping relationship between P and L is established as follows: Multiple electrodes with different corrosion rates are detected, and the proportion P of the number of pixels in the extracted corrosion area relative to the total number of pixels in the segmented electrode image is detected simultaneously. Then, a mapping relationship between P and L is constructed.

[0014] The beneficial effects of this invention are as follows: This invention sets up an internal resistance detection module, an electrode detection module, an audio detection module, and a power detection module, all of which are connected to the main controller. The internal resistance detection module, electrode detection module, audio detection module, and power detection module are all external modules, which are plugged into the host of the detection device through the plug hole. This makes the device more portable during detection, and each item can be detected separately or all items can be connected at the same time to detect all items, thus providing greater flexibility in use.

[0015] During testing, various aspects of the generator are measured simultaneously. The main controller comprehensively analyzes and calculates data from the internal resistance detection module, electrode detection module, audio detection module, and power detection module to obtain the generator life index F. Based on the generator life index F, the remaining lifespan of the generator is calculated. This method covers all factors affecting generator lifespan, resulting in more comprehensive and accurate testing. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Appendix Figure 1 This is a schematic diagram of the overall architecture of the present invention; Appendix Figure 2 This is a schematic diagram of the appearance and internal structure of the present invention. Detailed Implementation Example

[0018] See Figure 1-2 The present invention provides a portable aircraft generator life detection device, including a main unit, which includes an input module, a display unit, a main controller, a memory and an analysis module; It also features an internal resistance detection module, an electrode detection module, an audio detection module, and a power detection module; The input module, display unit, memory, and analysis module are all connected to the main controller; the internal resistance detection module, electrode detection module, audio detection module, and power detection module are also connected to the main controller. The internal resistance detection module is used to detect the internal resistance of the internal windings of the aircraft generator; the electrode detection module is used to detect the corrosion rate of the wiring electrodes of the aircraft generator; the audio detection module detects the sound when the aircraft generator is working; and the power detection module detects the generating voltage and output current of the aircraft generator when it is working. The internal resistance detection module, electrode detection module, audio detection module, and power detection module are all external modules, which are plugged into the main unit of the detection device through the plug-in hole; The main controller performs comprehensive analysis and calculation on the data detected by the internal resistance detection module, electrode detection module, audio detection module and power detection module to obtain the life index F of the aircraft generator; and calculates the remaining life of the aircraft generator based on the life index F. Example

[0019] See appendix Figure 2 The main unit includes an upper housing 1, a lower housing 2, a circuit board 3, a wire insertion hole assembly 4, an input module 5, a battery 6, a back clip 7, a display unit 8, and a shielding cover 9. The circuit board, battery, and shielding cover are housed inside the space formed by the upper and lower housings; the wiring hole assembly protrudes through the upper housing; the shielding cover is located at the bottom of the wiring hole assembly; the back clip is located on the outside of the lower housing; the display unit and input module are located on the outer surface of the upper housing; the display unit is a display screen, and the input module is an input keyboard.

[0020] Setting up a shield can minimize external interference to the detection sensor and improve the signal-to-noise ratio of the detection results. Example

[0021] The specific detection methods for each monitoring module are described below: The internal resistance detection module is equipped with a temperature sensor and a resistance detector; the temperature sensor detects the winding temperature of the aircraft generator in real time, and the resistance detector detects the change in resistance of the winding as the temperature changes; thereby generating a resistance-temperature curve, and further obtaining the resistance-temperature function B(T). The internal resistance detection module sends the resistance-temperature function B(T) to the main controller; the main controller stores it in its memory. The analysis module processes B(T) and differentiates it to obtain B'(T); it then differentiates B'(T) again to obtain B''(T); and calculates T1 corresponding to the maximum value and T2 corresponding to the minimum value of B''(T).

[0022] The electrode detection module is equipped with a corrosion rate detector. The electrode corrosion rate is measured using an image method, that is, the corrosion rate detector takes an image of the electrode position and sends the image to the main controller; the main controller obtains the electrode corrosion rate L after preprocessing the image. The corrosion rate detector is equipped with a standard color block. During the test, the standard color block is placed near the electrode, and the standard color block and the electrode are captured in one image to obtain the test image. The memory stores the standard values ​​of the RGB channels of the standard color blocks; the RGB channels of the detection image are adjusted to make the RGB values ​​of the standard color blocks in the detection image equal to the standard values, thereby achieving color calibration; After color calibration, the detection image is segmented to separate the electrode region from the detection image and process it separately to obtain a segmented electrode image. The main controller extracts the R values ​​of all pixels in the segmented electrode image and obtains the maximum value R1 of the R channel. Then, it extracts the region where the R value of all pixels exceeds 80% of R1 to obtain the pixels of the eroded region. It calculates the proportion P of the number of pixels in the extracted eroded region to the total number of pixels in the segmented electrode image and obtains the erosion rate L through the mapping relationship between P and L.

[0023] The audio detection module includes an audio acquisition unit, i.e., a microphone, which collects the sound of the aircraft generator when it is working, and divides the collected audio into 5-second segments, sending the audio segments to the main controller. At least 10 audio segments were collected, with a time interval of at least 5 seconds between each segment. The main controller processes the audio segment to obtain the average spectrum of the audio segment; and compares the average spectrum with the audio spectrum of the aircraft generator in a healthy state to calculate the similarity H. The main controller calculates the average similarity H0 of all audio segments and defines the audio risk coefficient R = 1 - H0.

[0024] The power detection module includes a voltage and current recorder, which detects the output voltage and current of the aircraft generator in real time and obtains voltage-time curves and current-time curves, and further obtains voltage-time function U(t) and current-time function I(t); The power detection module sends the voltage-time function U(t) and the current-time function I(t) to the main controller; The main controller calculates the standard deviation δ1 of the voltage-time function U(t) over a 1-minute time period and the standard deviation δ2 of the current-time function I(t) over a 1-minute time period.

[0025] The main controller stores the following data in its memory: the resistance-temperature function B(T) and B''(T) with maximum values ​​corresponding to T1 and minimum values ​​corresponding to T2, the electrode corrosion rate L, the audio risk coefficient R, the voltage-time function U(t), and the current-time function I(t).

[0026] The analysis module calculates the life index of the aircraft generator: F=F0-k1·[B(T1) / B(T2)]-k2·L- k3·R-k4·δ1-k5·δ2; F0 is the original maximum lifespan index; k1 to k5 are coefficients, which also represent the weights of each parameter. k1 to k3 are dimensionless values, k4 is in units of 1 / V, and k5 is in units of 1 / A. The analysis module also solves for Y based on the one-to-one correspondence between the aircraft generator life index F and the aircraft generator remaining life Y.

[0027] The one-to-one correspondence between the life index F of the aircraft generator and the remaining life Y of the aircraft generator is constructed as follows: the life index F of multiple brand-new aircraft generators is detected from the moment they are brand new and they are continuously operated until the aircraft generator is damaged and the remaining life is 0; the one-to-one correspondence between the detected life index F of the aircraft generator and the remaining life Y of the aircraft generator is established throughout the test process. The mapping relationship between P and L is established as follows: Multiple electrodes with different corrosion rates are detected, and the proportion P of the number of pixels in the extracted corrosion area relative to the total number of pixels in the segmented electrode image is detected simultaneously. Then, a mapping relationship between P and L is constructed.

[0028] Thus far, the description of the above embodiments has been provided for illustrative and descriptive purposes. This is not intended to be exhaustive or limiting of the present disclosure. Individual elements or features of particular embodiments are generally not limited to those particular embodiments, but may be interchanged and used in selected embodiments where applicable, even if not specifically shown or described. In many respects, the same elements or features may also be varied. Such variations are not considered a departure from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

[0029] Example embodiments are provided so that this disclosure will become thorough and will fully convey the scope to those skilled in the art. Numerous details, such as examples of specific parts, apparatus, and methods, are set forth to provide a thorough understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that the specific details are not required, and the example embodiments may be implemented in many different forms, neither of which should be construed as limiting the scope of this disclosure. In some example embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[0030] Technical terms are used herein for the purpose of describing specific exemplary embodiments only and are not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms “a” and “the” as used herein may also refer to the plural forms. The terms “comprising” and “having” are inclusive and therefore specify the presence of the stated features, integrals, steps, operations, elements, and / or components, but do not exclude the presence or additional having of one or more other features, integrals, steps, operations, elements, components, and / or combinations thereof. Unless expressly indicated in order of execution, the method steps, processes, and operations described herein are not to be construed as necessarily requiring performance in the specific order discussed and shown. It should also be understood that additional or optional steps may be employed.

Claims

1. A portable aircraft generator life testing device, comprising a main unit, the main unit including an input module, a display unit, a main controller, a memory, and an analysis module; characterized in that: It also features an internal resistance detection module, an electrode detection module, an audio detection module, and a power detection module; The input module, display unit, memory, and analysis module are all connected to the main controller; the internal resistance detection module, electrode detection module, audio detection module, and power detection module are also connected to the main controller. The internal resistance detection module is used to detect the internal resistance of the internal windings of the aircraft generator; the electrode detection module is used to detect the corrosion rate of the wiring electrodes of the aircraft generator; the audio detection module detects the sound when the aircraft generator is working; and the power detection module detects the generating voltage and output current of the aircraft generator when it is working. The internal resistance detection module, electrode detection module, audio detection module, and power detection module are all external modules, which are plugged into the main unit of the detection device through the plug-in hole; The main controller performs comprehensive analysis and calculation on the data detected by the internal resistance detection module, electrode detection module, audio detection module, and power detection module to obtain the life index F of the aircraft generator; and calculates the remaining life of the aircraft generator based on the life index F. The internal resistance detection module is equipped with a temperature sensor and a resistance detector; the temperature sensor detects the winding temperature of the aircraft generator in real time, and the resistance detector detects the change in resistance of the winding as the temperature changes; thereby generating a resistance-temperature curve, and further obtaining the resistance-temperature function B(T). The internal resistance detection module sends the resistance-temperature function B(T) to the main controller; The main controller stores it in memory; The analysis module processes B(T) and differentiates it to obtain B'(T); it then differentiates B'(T) again to obtain B''(T); and calculates T1 corresponding to the maximum value and T2 corresponding to the minimum value of B''(T).

2. The portable aircraft generator life testing device according to claim 1, characterized in that: The main unit includes an upper housing (1), a lower housing (2), a circuit board (3), a plug hole assembly (4), an input module (5), a battery (6), a back clip (7), a display unit (8), and a shielding cover (9); The circuit board, battery, and shielding cover are housed inside the space formed by the upper and lower housings; the wiring hole assembly protrudes through the upper housing; the shielding cover is located at the bottom of the wiring hole assembly; the back clip is located on the outside of the lower housing; the display unit and input module are located on the outer surface of the upper housing; the display unit is a display screen, and the input module is an input keyboard.

3. The portable aircraft generator life testing device according to claim 1, characterized in that: The electrode detection module is equipped with a corrosion rate detector. The electrode corrosion rate is measured using an image method, that is, the corrosion rate detector takes an image of the electrode position and sends the image to the main controller; the main controller obtains the electrode corrosion rate L after preprocessing the image. The corrosion rate detector is equipped with a standard color block. During the test, the standard color block is placed near the electrode, and the standard color block and the electrode are captured in one image to obtain the test image. The memory stores the standard values ​​of the RGB channels for the standard color blocks; The RGB channels of the detection image are adjusted to make the RGB values ​​of the standard color blocks in the detection image equal to the standard values, thereby achieving color calibration. After color calibration, the detection image is segmented to separate the electrode region from the detection image and process it separately to obtain a segmented electrode image. The main controller extracts the R values ​​of all pixels in the segmented electrode image and obtains the maximum value R1 of the R channel. Then, it extracts the region where the R value of all pixels exceeds 80% of R1 to obtain the pixels of the eroded region. It calculates the proportion P of the number of pixels in the extracted eroded region to the total number of pixels in the segmented electrode image and obtains the erosion rate L through the mapping relationship between P and L.

4. The portable aircraft generator life testing device according to claim 3, characterized in that: The audio detection module includes an audio acquisition unit, i.e., a microphone, which collects the sound of the aircraft generator when it is working, and divides the collected audio into 5-second segments, sending the audio segments to the main controller. At least 10 audio segments were collected, with a time interval of at least 5 seconds between each segment. The main controller processes the audio segment to obtain the average spectrum of the audio segment; and compares the average spectrum with the audio spectrum of the aircraft generator in a healthy state to calculate the similarity H. The main controller calculates the average similarity H0 of all audio segments and defines the audio risk coefficient R = 1 - H0.

5. The portable aircraft generator life testing device according to claim 4, characterized in that: The power detection module includes a voltage and current recorder, which detects the output voltage and current of the aircraft generator in real time and obtains voltage-time curves and current-time curves, and further obtains voltage-time function U(t) and current-time function I(t); The power detection module sends the voltage-time function U(t) and the current-time function I(t) to the main controller; The main controller calculates the standard deviation δ1 of the voltage-time function U(t) over a 1-minute time period and the standard deviation δ2 of the current-time function I(t) over a 1-minute time period.

6. The portable aircraft generator life testing device according to claim 5, characterized in that: The main controller stores the following data in its memory: the resistance-temperature function B(T) and B''(T) with maximum values ​​corresponding to T1 and minimum values ​​corresponding to T2, the electrode corrosion rate L, the audio risk coefficient R, the voltage-time function U(t), and the current-time function I(t).

7. The portable aircraft generator life testing device according to claim 5, characterized in that: The analysis module calculates the life index of the aircraft generator: F=F0-k1·[B(T1) / B(T2)]-k2·L- k3·R-k4·δ1-k5·δ2; F0 is the original maximum lifespan index; k1 to k5 are coefficients, which also represent the weights of each parameter. k1 to k3 are dimensionless values, k4 is in units of 1 / V, and k5 is in units of 1 / A. The analysis module also solves for Y based on the one-to-one correspondence between the aircraft generator life index F and the aircraft generator remaining life Y.

8. The portable aircraft generator life testing device according to claim 7, characterized in that: The one-to-one correspondence between the life index F of the aircraft generator and the remaining life Y of the aircraft generator is constructed as follows: the life index F of multiple brand-new aircraft generators is detected from the moment they are brand new and they are continuously operated until the aircraft generator is damaged and the remaining life is 0; the one-to-one correspondence between the detected life index F of the aircraft generator and the remaining life Y of the aircraft generator is established throughout the test process. The mapping relationship between P and L is established as follows: Multiple electrodes with different corrosion rates are detected, and the proportion P of the number of pixels in the extracted corrosion area relative to the total number of pixels in the segmented electrode image is detected simultaneously. Then, a mapping relationship between P and L is constructed.

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