A method and apparatus for monitoring a composite material runner plate test

Abstract

Disclosed are a composite material flow channel plate test monitoring method and device. An engine can include a fan disc and a bearing seat serving as a fulcrum of the fan disc, a plurality of composite material flow channel plates are installed on the fan disc, the fan disc is fixed on a rotating shaft supported by the bearing seat and rotates with the rotating shaft during engine test running. The fulcrum vibration detected by the vibration sensor installed on the bearing seat can be monitored during the engine test running. If the fulcrum vibration is abnormal, the engine test running process is stopped and the flow channel plate is nondestructively detected to obtain a nondestructive detection state of the flow channel plate, and whether the state of the flow channel plate is normal can be determined based on whether the nondestructive detection state of the flow channel plate exceeds a permissible defect range.

Description

Technical Field

[0001] This invention relates to the field of engine testing, and more specifically to a method and apparatus for monitoring the testing of composite material flow channel plates. Background Technology

[0002] High bypass ratio, high thrust, low fuel consumption, low noise, high safety, and high reliability are the goals that modern civil aero engines have always pursued. Resin-based composite materials, due to their high strength, good fatigue performance, and corrosion resistance, can meet the stringent strength requirements of aero engines while significantly reducing engine weight. Therefore, resin-based composite materials are widely used in modern civil aero engines, such as composite flow channels, composite blades, and composite casings. Because of the significant differences between composite components and metal components, their development is far more challenging than that of metal components.

[0003] The structure of a flow channel plate is far more complex than that of a blade, containing numerous holes, fillets, and transition zones. When designed and manufactured using composite materials, resin-filled areas are unavoidable. Furthermore, to ensure the aerodynamic performance of the fan and turbocharger stage, rubber strips are attached to both sides of the flow channel plate for sealing. These locations are all potential risk points during engine performance testing and overall engine testing. During engine testing, there have been instances of rubber strips flying off and flow channel plates detaching due to cracks. These foreign objects could potentially enter the engine and cause serious accidents such as blade damage. Simultaneously, changes in imbalance can worsen overall engine vibration, leading to scuffing and other malfunctions, posing serious hidden dangers to engine testing.

[0004] Therefore, to ensure the safety of engine testing, there is a need in the art for a method and apparatus for monitoring the testing of composite material flow channel plates. Summary of the Invention

[0005] One technical problem this invention aims to solve is to provide an effective monitoring method and / or device for the commissioning of composite material runner plates. Another technical problem this invention aims to solve is to provide a method for judging non-destructive defects in composite material runner plates. Additionally, this invention also provides a static tensile testing method and / or a rotational testing method for composite material runner plates.

[0006] This invention proposes a method for monitoring the flow channel plate during engine testing. By monitoring the flow channel plate during engine testing, the operating status of the flow channel plate can be obtained in a timely manner, avoiding uncontrollable risks to the overall engine testing due to abnormal conditions, and supporting the smooth completion of the test. At the same time, it can obtain non-destructive data of the flow channel plate during engine testing, providing reliable test data support for subsequent airworthiness certification.

[0007] In one embodiment of the present invention, a method for monitoring the test run of a composite material flow channel plate is provided, comprising: performing an engine test run, the engine including a fan disk and a bearing housing serving as a fulcrum for the fan disk, a plurality of composite material flow channel plates being mounted on the fan disk, the fan disk being fixed on a rotating shaft supported by the bearing housing and rotating with the rotating shaft during the engine test run; monitoring the vibration of the fulcrum detected by a vibration sensor mounted on the bearing housing during the engine test run; stopping the engine test run if the fulcrum vibration is abnormal; performing non-destructive testing on the composite material flow channel plate to obtain the non-destructive testing status of the composite material flow channel plate; and determining whether the state of the composite material flow channel plate is normal based on whether the non-destructive testing status of the composite material flow channel plate exceeds the allowable defect range.

[0008] In one aspect, the composite material flow channel plate test monitoring method further includes: if the vibration amplitude of the fulcrum vibration is within the corresponding amplitude threshold range of the corresponding rotation speed, then the fulcrum vibration is determined to be normal; or if the vibration amplitude of the fulcrum vibration exceeds the corresponding amplitude threshold range of the corresponding rotation speed, then the fulcrum vibration is determined to be abnormal.

[0009] In one aspect, the permissible defect range includes no defects, the presence of point defects, or the presence of linear defects, wherein if the non-destructive testing status indicates the presence of cracks and / or area defects, the condition of the composite material flow channel plate is determined to be abnormal.

[0010] In one aspect, the composite material flow channel plate test monitoring method further includes: if the engine test process is stopped due to abnormal vibration of the fulcrum, then determining the highest speed that has been executed during the engine test process; and comparing the non-destructive testing state of the composite material flow channel plate with the reference state corresponding to the highest speed to determine whether the state of the composite material flow channel plate is normal.

[0011] In one aspect, the test monitoring method for the composite material flow channel plate further includes: if the non-destructive testing status of the composite material flow channel plate is better than or equal to the reference status corresponding to the highest speed, then the state of the composite material flow channel plate is determined to be normal; or if the non-destructive testing status of the composite material flow channel plate is worse than the reference status corresponding to the highest speed, then the state of the composite material flow channel plate is determined to be abnormal.

[0012] In one respect, the reference state is determined based on one or more of the following: the quality specifications of the composite material flow channel plate; the non-destructive testing status at various equivalent speeds obtained by static tensile testing of a second flow channel plate having the same material and specifications as the composite material flow channel plate; and / or the non-destructive testing status at various speeds obtained by rotational testing of a third flow channel plate having the same material and specifications as the composite material flow channel plate.

[0013] In one aspect, the reference state includes the rotational speed and corresponding non-destructive testing state when the initial crack appears, and the rotational speed and corresponding non-destructive testing state when the load-bearing capacity is lost.

[0014] On one hand, the non-destructive testing status of the plurality of composite material flow channels before the engine test is superior to or equivalent to the non-destructive testing status of the second flow channel before the static tensile test and the non-destructive testing status of the third flow channel before the rotation test.

[0015] In one aspect, the nondestructive testing status includes one or more of the following: defect type, defect size, and defect location.

[0016] In one embodiment of the present invention, a composite material flow channel plate test monitoring device is provided, comprising: a vibration sensor mounted on a bearing housing in an engine, the bearing housing serving as a fulcrum for a fan disc, a plurality of composite material flow channel plates being mounted on the fan disc, the fan disc being fixed on a rotating shaft supported by the bearing housing and rotating with the rotating shaft during engine testing, the vibration sensor being used to detect fulcrum vibration during engine testing; a test control device, wherein if the fulcrum vibration is abnormal, the test control device stops the engine testing process; a non-destructive testing device, which performs non-destructive testing on the composite material flow channel plate to obtain the non-destructive testing status of the composite material flow channel plate; and a status judgment device, which determines whether the status of the composite material flow channel plate is normal based on whether the non-destructive testing status of the composite material flow channel plate exceeds the allowable defect range.

[0017] On one hand, the composite material flow channel plate test monitoring device further includes: a vibration processing device, which determines that the vibration of the support point is normal if the vibration amplitude of the support point is within the corresponding amplitude threshold range of the corresponding rotation speed; or determines that the vibration of the support point is abnormal if the vibration amplitude of the support point exceeds the corresponding amplitude threshold range of the corresponding rotation speed.

[0018] In one aspect, the permissible defect range includes no defects, the presence of point defects, or the presence of linear defects, wherein if the non-destructive testing status indicates the presence of cracks and / or area defects, the status determination device determines that the state of the composite material flow channel plate is abnormal.

[0019] On the one hand, if the engine test process is stopped due to abnormal vibration of the fulcrum, the test control device determines the highest speed that has been executed during the engine test, and the state judgment device compares the non-destructive testing state of the composite material flow channel plate with the reference state corresponding to the highest speed to determine whether the state of the composite material flow channel plate is normal.

[0020] On one hand, if the non-destructive testing status of the composite material flow channel plate is better than or equal to the reference status corresponding to the highest rotational speed, the status determination device determines that the composite material flow channel plate is in normal condition; or if the non-destructive testing status of the composite material flow channel plate is worse than the reference status corresponding to the highest rotational speed, the status determination device determines that the composite material flow channel plate is in abnormal condition.

[0021] In one respect, the reference state is determined based on one or more of the following: the quality specifications of the composite material flow channel plate; the non-destructive testing status at various equivalent speeds obtained by static tensile testing of a second flow channel plate having the same material and specifications as the composite material flow channel plate; and / or the non-destructive testing status at various speeds obtained by rotational testing of a third flow channel plate having the same material and specifications as the composite material flow channel plate.

[0022] In one aspect, the reference state includes the rotational speed and corresponding non-destructive testing state when the initial crack appears, and the rotational speed and corresponding non-destructive testing state when the load-bearing capacity is lost.

[0023] On one hand, the non-destructive testing status of the plurality of composite material flow channels before the engine test is superior to or equivalent to the non-destructive testing status of the second flow channel before the static tensile test and the non-destructive testing status of the third flow channel before the rotation test.

[0024] In one aspect, the nondestructive testing status includes one or more of the following: defect type, defect size, and defect location. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of an aircraft engine fan according to an embodiment of the present invention.

[0026] Figure 1A This is a schematic diagram of the bearing housing of an aircraft engine fan according to an embodiment of the present invention.

[0027] Figure 2 This is a flowchart of a composite material flow channel plate test monitoring method according to an embodiment of the present invention.

[0028] Figure 3This is a schematic diagram of the vibration response under a typical test condition according to an embodiment of the present invention.

[0029] Figure 4 This is a schematic diagram of a static test of a composite material flow channel plate according to an embodiment of the present invention.

[0030] Figure 5 This is a schematic diagram of a rotation test of a composite material flow channel plate according to an embodiment of the present invention.

[0031] Figure 6 This is a flowchart of a composite material flow channel plate test monitoring method according to an embodiment of the present invention.

[0032] Figure 7 This is a block diagram of a composite material flow channel plate test monitoring device according to an embodiment of the present invention. Detailed Implementation

[0033] The present invention will be further described below with reference to specific embodiments and accompanying drawings, but this should not be construed as limiting the scope of protection of the present invention.

[0034] In the engine development cycle, it goes through design, testing, product finalization, and approval before mass production. Among these, test runs, such as performance tests, applicability tests, durability tests, environmental tests, and flight tests, are an extremely important part. They are key links in engine product finalization and airworthiness certification. Therefore, monitoring various risks during engine testing is particularly important for the smooth development of the engine.

[0035] Figure 1 This is a schematic diagram of the structure of an aircraft engine fan 100 according to an embodiment of the present invention.

[0036] The aircraft engine fan 100 may include an intake cone 101, a booster stage drum 105, and a fan disk 110 disposed between the rear section of the intake cone and the booster stage drum. Multiple fan blades 111 may be circumferentially spaced on the fan disk 110, and a flow passage plate 112 may be disposed between the roots of two adjacent fan blades 111 and fixed to the fan disk. A booster stage drum seal 106 may also be included between the fan disk 110 and the booster stage drum 105. The flow passage plate 112, the intake cone 101, and the booster stage drum seal 106 form the gas flow channel of the engine intake section. When the fan blades 111 rotate, they draw air into the engine duct, and some of the air enters the duct, passes through the compressor, and enters the combustion chamber for combustion.

[0037] Compared to metal runner plates, composite runner plates can reduce engine weight and offer advantages such as high strength, good fatigue performance, and corrosion resistance. As an example, and not a limitation, the composite materials used for runner plates can be resin-matrix composites, aluminum-based composites, etc. Resin-matrix composites refer to fiber-reinforced materials with organic polymers as the matrix; commonly used fiber-reinforced materials include glass fiber, carbon fiber, and aramid fiber.

[0038] Before being put into service or production, assembled, installed, and repaired aero engines undergo trial runs (i.e., test runs) to obtain relevant test data, verify whether the engine performance meets the standards, and provide technical direction for subsequent optimization. Engine test runs refer to developing a test program according to the requirements of engine test subjects and carrying out corresponding test items on a test bench. Flow channels include holes, fillets, transition areas, etc. Flow channels made of composite materials inevitably have resin filler areas. Additionally, to ensure the aerodynamic performance of the fan and booster stage, rubber strips are attached to both sides of the flow channel to seal with the blades. These locations are all potential risk points in engine performance test components and overall engine test runs.

[0039] Accordingly, the present invention provides a test monitoring method and device for composite material flow channel plates. By monitoring the flow channel plates during engine testing, the operating status of the flow channel plates can be obtained in a timely manner, avoiding uncontrollable risks to the overall engine test due to abnormal conditions. At the same time, non-destructive data of the flow channel plates during engine testing can be obtained to provide reliable test data support for subsequent airworthiness certification.

[0040] Figure 1A This is a schematic diagram of the structure of a bearing housing 130 for an aircraft engine fan according to an embodiment of the present invention. The bearing housing 130 can serve as a fulcrum for the fan disc 110. The bearing housing 130 is located within the engine, for example, fixed to the engine housing, which can be fixed to a test stand. Alternatively, the bearing housing 130 can be located within the engine body, which is fixed to the test stand via a mounting joint. In other embodiments, the bearing housing 130 can also be fixed to other components within the engine. The fan disc 110 is mounted (e.g., fixed) on a shaft 120, which is supported by the bearing housing 130. For example, the bearing housing 130 contains a bearing 131, and the shaft 120 passes through and is supported by the bearing 131. The shaft 120 can be rotated by a motor, thereby causing the fan disc 110 to rotate.

[0041] As described above, the bearing housing 130 (including the bearing 131) can serve as a fulcrum for the fan disc 110. The fan disc 110 may vibrate during rotation and transmit the vibrations to the bearing housing 130 via the shaft 120. According to one embodiment of the invention, one or more vibration sensors 132, such as acceleration sensors, velocity sensors, displacement sensors, etc., can be mounted on the bearing housing 130 to measure fulcrum vibration. By way of example and not limitation, vibration sensors can be mounted near the shaft support point on the bearing housing 130 (e.g., the bearing 131 supporting the shaft) for monitoring bearing housing vibration (i.e., fulcrum vibration) during engine testing. It should be understood that the position of the vibration sensors on the bearing housing 130 is not limited, and one or more vibration sensors can be mounted at suitable locations on the bearing housing 130 depending on the specific application. On the other hand, mounting vibration sensors on the bearing housing 130 near the bearing 131 (or on a stationary part of the bearing 131) can improve the accuracy of the detected fulcrum vibrations.

[0042] Figure 2 This is a flowchart of a composite material flow channel plate test monitoring method according to an embodiment of the present invention.

[0043] In step 201, an engine test is performed. The engine includes a fan disk and a bearing housing serving as a fulcrum for the fan disk. Multiple composite material flow channels are mounted on the fan disk, which is fixed to a shaft supported by the bearing housing and rotates with the shaft during the engine test. In a preferred embodiment, the flow channels can be paired according to their moment of weight, with the paired flow channels installed diagonally to reduce engine imbalance forces. For example, the paired flow channels have a moment of weight difference below a threshold. The engine test may include conducting relevant tests on a test bench, such as engine performance tests, suitability tests, durability tests, environmental tests, and flight tests, and obtaining test data. During the engine test, the engine can be operated at various predetermined speeds.

[0044] During engine testing, in step 202, the vibration of the fulcrum is monitored by a vibration sensor mounted on the bearing housing. As described above, the fan disc is mounted on a shaft, which is supported by a bearing housing, which thus serves as the fulcrum for the fan disc. Vibration sensors, such as acceleration sensors, velocity sensors, and displacement sensors, can be mounted on the bearing housing (e.g., near the connection between the shaft and the bearing housing) to measure the fulcrum vibration. By way of example and not limitation, this bearing fulcrum is typically fulcrum #1 in an aero-engine. Vibration monitoring of the fulcrum during testing is primarily used to monitor the risk of the flow channel plate rubber strip and the flow channel plate body flying off during the test run. When loosening or flying off occurs, the imbalance changes, thus causing changes in the fulcrum vibration.

[0045] In step 203, it is determined whether the fulcrum vibration is abnormal. For example, if the vibration amplitude is within the corresponding amplitude threshold range for the corresponding speed, the vibration is determined to be normal. Conversely, if the vibration amplitude exceeds the corresponding amplitude threshold range for the corresponding speed, the vibration is determined to be abnormal. The amplitude threshold range can refer to the fulcrum vibration amplitude that may occur during test runs under normal engine conditions. Taking displacement monitoring as an example, the "amplitude threshold range" can be, for example, 0–0.10 mm, 0–0.14 mm, 0–0.18 mm, etc.

[0046] In another example, the vibration of the current test run can be compared to that of the last successful test run. The last successful test run refers to the previous test run where the vibration was within a predetermined amplitude threshold range under the same engine configuration. If a previous successful test run meets this condition, then a vibration anomaly can be considered present if the vibration amplitude of the current test run exceeds a predetermined percentage (e.g., 8%, 10%, 12%, etc.) of the vibration amplitude at the corresponding speed in the last successful test run. On-site personnel can then determine whether to shut down the test run if the vibration response is abnormal.

[0047] If no vibration abnormality occurs, the method continues with the test run at step 201 until completion. If a vibration abnormality occurs, in step 204, the engine can be stopped, and then non-destructive testing of the flow channel plate can be performed. Non-destructive testing (NDT) refers to methods that, without damaging or affecting the performance of the tested object or its internal structure, utilize changes in thermal, acoustic, optical, electrical, and magnetic responses caused by abnormalities or defects in the material's internal structure. These methods employ physical or chemical means, utilizing modern technology and equipment, to detect and test the structure, state, and type, quantity, shape, nature, location, size, distribution, and changes of defects within and on the surface of a test piece. As an example and not a limitation, NDT can include ultrasonic testing, liquid penetrant testing, etc.

[0048] As an example and not a limitation, the non-destructive testing in step 204 can determine the non-destructive testing status of the flow channel plate, such as the type of non-destructive defect (e.g., point defects, linear defects, area defects, cracks, etc.), defect size, and defect location. Additionally, step 204 can also perform a visual inspection of the installation status and internal structural status of the flow channel plate, such as determining whether there are visible cracks, rubber strips flying off, or flow channel plate detachment.

[0049] In step 205, the condition of the flow channel plate is determined to be normal based on whether the non-destructive testing status of the flow channel plate exceeds the allowable defect range.

[0050] In the first embodiment, the permissible defect range may include no defects, the presence of point defects, or the presence of linear defects. Accordingly, in step 205, if the non-destructive testing status of the runner plate indicates no defects, the presence of point defects, and / or the presence of linear defects, the runner plate is considered to be in normal condition. If the installation status of the runner plate is also ensured to be normal, the method can return to step 201 to continue / re-perform engine testing. Conversely, if the non-destructive testing status indicates cracks and / or area defects (i.e., exceeding the permissible defect range), the runner plate is determined to be in abnormal condition and cannot continue to be used for testing.

[0051] In the second embodiment, the permissible defect range may refer to the baseline state corresponding to the highest speed. Accordingly, in step 205, the highest speed achieved during engine testing can be determined, and the non-destructive testing state of the runner plate after testing is compared with the judgment criteria to determine whether the runner plate is in normal condition. The judgment criteria may include the baseline state of the runner plate at various speeds (e.g., a normally functioning state, a permissible defect range, etc.). In one example, the judgment criteria may be a quality specification based on a runner plate made of a specified composite material. In another example, the judgment criteria may be determined based on strength testing of the runner plate made of the composite material. For example, for a batch of runner plates of the same specifications formed from the same composite material, where multiple runner plates (first runner plates) can be installed on an engine for testing, and one or more other runner plates can undergo strength testing to obtain a non-destructive testing state at various speeds as a baseline state. By way of example and not limitation, one or more second runner plates may undergo static tensile testing to obtain a non-destructive testing state at various equivalent speeds, and / or one or more third runner plates may undergo rotational testing to obtain a non-destructive testing state at various speeds. Accordingly, the non-destructive testing status of the first flow channel plate after the test run can be determined by comparing it with the baseline state obtained through the strength test.

[0052] If the non-destructive testing (defect type, defect size, and number of defects, etc.) of the flow channel plate after the actual test run is better than or equal to the baseline state at the corresponding highest speed (e.g., fewer defects and smaller defect sizes in the non-destructive testing of the flow channel plate after the test run), then the flow channel plate is determined to be in normal condition after the test run. If the installation condition of the flow channel plate is also ensured to be normal, the method can return to step 201 to continue / re-perform the engine test run.

[0053] If the non-destructive testing status (defect type, defect size, and number of defects, etc.) of the flow channel plate after the actual test run exceeds the baseline status at the corresponding maximum speed (e.g., more defects, larger defect size, etc.), then the flow channel plate after the test run is determined to be in an abnormal state.

[0054] For example, point defects are better than linear defects, linear defects are better than area defects, and area defects are better than visible cracks. For the same type of defect, fewer defects (or smaller sizes) are better than more defects (or larger sizes).

[0055] In another example, the first and second embodiments can be implemented in combination. If the non-destructive testing (NDT) status indicator of the flow channel plate after actual testing shows no defects, the flow channel plate is considered normal. If the NDT status indicator of the flow channel plate after actual testing shows area defects or visible cracks, the flow channel plate is determined to be abnormal and cannot be used for further testing. If the NDT status indicator of the flow channel plate after actual testing shows point defects and / or linear defects, it can be further determined whether the NDT status of the flow channel plate after actual testing is better than or equal to the reference status at the corresponding highest speed. If so, the flow channel plate is considered normal. Conversely, if the NDT status of the flow channel plate after actual testing is worse than the reference status at the corresponding highest speed, the flow channel plate is considered abnormal and cannot be used for further testing.

[0056] In optional step 206, it can be determined whether to replace the flow channel plate. If there are other flow channel plates to be tested, the flow channel plate can be replaced and the process can return to step 201 to re-test the engine. In a preferred embodiment, flow channel plate replacement can be performed in pairs to ensure weight moment matching. If there are no other flow channel plates to be tested, the method can end.

[0057] In addition, after the engine test is successfully completed, steps 204 and 205 can be executed to obtain the non-destructive testing status of the flow channel plate after the successful test and to perform performance analysis.

[0058] By execution Figure 2 The composite material runner plate test monitoring method can monitor and control the state of the composite material runner plate during engine testing, avoiding risks to the overall engine testing caused by abnormal runner plate conditions. Furthermore, it can obtain the runner plate's state under different test conditions, and this information can be used for performance analysis and design / manufacturing improvements of the composite material runner plate.

[0059] Figure 3 This is a schematic diagram of the vibration response under a typical test condition according to an embodiment of the present invention, which shows the amplitude of the fulcrum vibration (vertical axis) detected at different speeds (horizontal axis).

[0060] As an example, and not a limitation, vibration monitoring can be performed using a frequency domain fundamental frequency displacement value and rotation graph. This involves using the frequency calculated based on the rotational speed as the fundamental frequency, then calculating the displacement value corresponding to the fundamental frequency, and plotting the displacement value as a curve changing with the rotational speed. If the detected vibration response exceeds a threshold, for example, an amplitude increase of more than 10% compared to the reference vibration waveform, the fulcrum vibration can be considered abnormal, and the system should be stopped for inspection.

[0061] Figure 4 This is a schematic diagram of a static test of a composite material flow channel plate according to an embodiment of the present invention.

[0062] Static tensile testing is mainly used to simulate the strength and safety of flow channel plates when subjected to centrifugal force. A tensile testing machine is used to load the flow channel surface. Since the flow channel plate is subjected to body force, the loads at different locations are not the same.

[0063] The flow channel plate test piece is divided into two parts according to its dimensions, with corresponding masses and centroids of m1, x1 and m2, x2, respectively. A first-order lever is used for loading, and the lengths L1 and L2 on both sides of the lever must meet the following requirements:

[0064] L1 + L2 = x1 + x2 (1)

[0065] m1*L1=m2*L2 (2)

[0066] In one aspect, conformal metal gaskets are installed on both sides of the loading position and effectively connected by bolts and the loading system to avoid surface delamination caused by adhesive bonding, which would lead to premature failure of the test specimen and test failure.

[0067] The loading system spindle can rotate 360°. The horizontal lever and the force transmission rod, as well as the force transmission rod and the loading block, are connected by ball joints, thereby enabling adaptive adjustment of the loading load and avoiding additional torque and bending moment.

[0068] Static tests will be conducted to obtain the equivalent rotational speed and corresponding non-destructive testing (NDT) status when various defects (e.g., point defects, linear defects, area defects, initial cracks, etc.) appear, as well as the equivalent rotational speed and corresponding NDT status when the load-bearing capacity is lost. The NDT status includes the type, size, and location of the non-destructive defects. The obtained rotational speed and corresponding defect status can be used as a benchmark for judging defects in composite material flow channel plates.

[0069] Figure 5 This is a schematic diagram of a rotation test of a composite material flow channel plate according to an embodiment of the present invention.

[0070] Rotational testing refers to the test conducted on a rotational testing machine to assess the static strength and low-cycle fatigue strength of a flow channel plate under actual centrifugal force. In one embodiment, a simulated rotational test piece can be fabricated and assembled based on the actual working condition of the flow channel plate, such as... Figure 5The diagram illustrates the use of various aero-engine simulators to simulate the installation state of composite material runner plates. Based on test parameters, the rotational speeds for the rotational tests and the maximum rotational speeds and cycle numbers for low-cycle fatigue were determined to obtain the corresponding rotational speeds when various defects (e.g., point defects, linear defects, area defects, initial cracks, loss of load-bearing capacity, etc.) occur. The obtained rotational speeds and corresponding defect states can be used as criteria for judging defects in composite material runner plates.

[0071] It should be understood that Figure 4 and Figure 5 The static and rotational tests shown are merely examples and not limitations. In practice, other testing equipment and configurations can be used to perform static and rotational tests on the flow channel plate to obtain the corresponding rotational speeds when various defects occur, without departing from the scope of the invention.

[0072] Figure 6 This is a flowchart of a composite material runner plate test monitoring method 600 according to an embodiment of the present invention. In one specific implementation, the runner plate test method, runner plate static test, and rotation test described above can be used in combination. However, it should be understood that in different embodiments, the runner plate test method, runner plate static test, and rotation test can be implemented individually or in other ways, without having to be implemented all at once.

[0073] In step 601, a benchmark flow channel plate can be determined. For example, multiple flow channel plates can be mass-produced, which can be made of the same material and have the same specifications, such as shape and size. The produced flow channel plates can be subjected to non-destructive testing, and the non-destructive testing signal for each flow channel plate can be obtained.

[0074] Various non-destructive testing (NDT) techniques can be used to obtain NDT signals for flow channel plates, such as ultrasonic testing and liquid penetrant testing. NDT signals characterize the NDT status, indicating whether the flow channel plate has defects such as porosity or delamination. Porosity and delamination defects can be further classified as point-like, linear, or area-like. NDT signals can also indicate the size and location of defects. If two flow channel plates have the same NDT signals, their NDT status can be considered identical.

[0075] Benchmark flow channel plates can be one or more flow channel plates whose non-destructive testing (NDT) signals just meet a minimum standard (e.g., just pass). For example, flow channel plates that do not meet the minimum standard can be considered unqualified and therefore will not be used in subsequent testing or use. In other embodiments, benchmark flow channel plates can also be those flow channel plates whose NDT signals are within a specified range, such as flow channel plates with the second worst NDT signals, the second best NDT signals, the best NDT signals, etc.

[0076] In step 602, flow channel plates for use as strength test specimens and flow channel plates for use as assembly parts can be determined. For example, flow channel plates for use as strength test specimens and flow channel plates for use as assembly parts can be screened based on the non-destructive testing (NDT) signals of benchmark flow channel plates. By way of example and not limitation, one or more flow channel plates with the worst NDT signals among the benchmark flow channel plates determined in step 601 can be used as strength test specimens, and other flow channel plates with NDT signals better than those of the strength test specimens can be used as assembly parts. The number of strength test specimens and assembly parts can be set as needed. In one example, spare parts for assembly parts are prepared in addition to the requirement of 0.5 times the number of assembly parts and rounded to an even number.

[0077] While steps 601 and 602 describe the screening of strength test specimens and assemblies for runner plates, it should be understood that other methods may be used to determine the strength test specimens and assemblies. For example, runner plates meeting specified requirements may be screened from qualified runner plates as test specimens and assemblies as needed, or test specimens and assemblies may be randomly selected from qualified runner plates. These test specimens and assemblies may come from the same production batch or different production batches. Generally, the selected test specimens and assemblies are made of the same composite material and may have the same specifications, such as shape and size.

[0078] In optional step 640, a static tensile test can be performed on at least one strength test specimen (e.g., a second flow channel plate) to obtain the equivalent rotational speed at which various defects occur. For example, as the tensile force increases, the test specimen may exhibit point defects, point defects forming line defects, line defects expanding into area defects, visible cracks appearing, or loss of load-bearing capacity. The static tensile test can be performed as described herein. Figure 4 The method described can also be implemented using other suitable static tensile tests.

[0079] In optional step 650, at least one strength test specimen (e.g., a third flow channel plate) may be subjected to a rotational test to obtain the corresponding rotational speeds at which various defects occur. For example, as the rotational speed increases, the specimen may exhibit point defects, point defects forming line defects, line defects expanding into area defects, visible cracks appearing, or loss of load-bearing capacity. It should be noted that the static tensile test and rotational test in steps 640 and 650 are performed using different strength test specimens.

[0080] In optional step 660, the defect states corresponding to different rotational speeds can be obtained from the static tensile test in step 640 and the rotational test in step 650 as non-destructive testing signal standards. These can include the rotational speeds corresponding to the initial crack appearance and loss of load-bearing capacity. The non-destructive testing state can include the non-destructive defect form, defect size, and defect location. As an example and not a limitation, the results of the static tensile test include the converted rotational speed and the corresponding non-destructive testing state, and the results of the rotational test include the rotational speed and the corresponding non-destructive testing state. Therefore, the results of the static tensile test and the rotational test can be combined to obtain the non-destructive testing state at various rotational speeds (including the converted rotational speed). When the same crack appears in both the static tensile test and the rotational test, the lower corresponding rotational speed can be selected as the corresponding rotational speed for that crack.

[0081] For example, the non-destructive testing signal standard obtained in step 660 can be represented by a table:

[0082] rotational speed Test status Non-destructive testing status Rotation speed 1 Safe to operate Point defects Rotation speed 2 Safe to operate linear defects 3 RPM flow channel plate abnormality Area defects 4 RPM flow channel plate abnormality Visible cracks 5 RPM flow channel plate abnormality Loss of load-bearing capacity … … …

[0083] Table 1: Nondestructive Testing Status Standards

[0084] In step 603, the mounting components (e.g., multiple first flow channel plates) can be installed. In a preferred embodiment, the flow channel plates can be paired according to their weight moments, with the paired flow channel plates installed diagonally to reduce engine imbalance forces. The weight moment can be expressed as mass x radius of gyration, i.e., mr. For example, in one implementation, the flow channel plates can be arranged in descending order of their weight moments, and then the difference in weight moments between adjacent flow channel plates can be calculated. If the difference in weight moments is less than a threshold (e.g., 1.1 kg·m), the two flow channel plates are considered a pair, and flow channel plates with matching weight moments are selected accordingly. In other implementations, the flow channel plates can be installed according to other suitable standards to ensure that the engine meets test requirements.

[0085] In step 604, an engine test is performed. The engine test may include, for example, engine performance tests, suitability tests, durability tests, environmental tests, and flight tests, and test data may be obtained.

[0086] According to one embodiment of the present invention, during engine test runs, in step 611, the vibration of the bearing support of the flow channel plate can be monitored, such as the vibration of the bearing housing for the fan disc described above. As an example and not a limitation, this is typically the #1 support in an aero-engine. If abnormal vibration occurs, such as the vibration amplitude exceeding the amplitude threshold range, or the vibration amplitude increasing by more than 10% (or other percentages, such as 8%, 12%, etc.) compared to the previous successful test run, the engine is stopped, and a post-test visual inspection (step 620) and a post-test non-destructive testing (step 630) are performed. If no abnormal vibration occurs, the current engine test run continues until its end, and a post-test visual inspection (step 620) and a post-test non-destructive testing (step 630) are performed again.

[0087] The visual inspection (step 620) and non-destructive testing (step 630) after the test run are mainly used to monitor the installation status and internal structural status of the flow channel plate.

[0088] In step 631, the non-destructive testing (NDT) status after the test run can be compared with a judgment criterion (e.g., a baseline defect status) to determine whether the runner plate is normal. For example, the baseline defect status could be the allowable defect range and / or the baseline defect status corresponding to the highest speed tested in the NDT signal criterion obtained in step 660. If the actual NDT status (defect type, defect size, and defect number) of the runner plate after the test run exceeds the baseline defect status, the runner plate after the test run is determined to be abnormal. Conversely, if the NDT status of the runner plate after completing the required test run is better than or equal to the NDT signal criterion (i.e., the actual damage after the test run is lower than the NDT signal criterion), the runner plate is normal and can be used in an actual engine.

[0089] Based on one implementation described in this article, the following judgment method can be used:

[0090] (i) Monitoring the vibration of the bearing support point of the flow channel plate during engine test runs.

[0091] 1. If no abnormal vibration is observed, continue this test run;

[0092] 2. If abnormal vibration is detected, the machine needs to be stopped for visual inspection and non-destructive testing. Refer to Table 1 for further information.

[0093] a) If there are visible cracks, replace the flow channel plate;

[0094] b) If there are no visible cracks, but non-destructive testing reveals area defects, the flow channel plate also needs to be replaced.

[0095] c) If there are no visible cracks or area defects, but there are dot-shaped or linear defects, then there is no need to replace the runner plate and the test run can continue.

[0096] (i) In an optional embodiment, if there are no visible cracks or area defects, but there are point defects or line defects, and the point defects or line defects are better than or equivalent to the reference defect state corresponding to the highest speed of the test run, the flow channel plate can be considered to be normal, and there is no need to replace the flow channel plate and continue the test run.

[0097] (ii) In an optional embodiment, if there are no visible cracks or area defects, but there are point defects or line defects, and the point defects or line defects are worse than the reference defect state corresponding to the highest speed of the test run, then the flow channel plate is considered to be abnormal and the flow channel plate needs to be replaced and the test run should be repeated.

[0098] d) If there are no visible cracks, no area defects, and no point or line defects, then there is no need to replace the runner plate, and the test run can continue.

[0099] (II) After this test run, visual inspection and non-destructive testing shall be carried out, namely...

[0100] a) If there are visible cracks, replace the flow channel plate;

[0101] b) If there are no visible cracks, but non-destructive testing reveals area defects, the flow channel plate also needs to be replaced.

[0102] c) If there are no visible cracks or area defects, but there are dot-shaped or linear defects, then there is no need to replace the runner plate; proceed to the next test run.

[0103] d) If there are no visible cracks, area defects, point defects, or line defects, then there is no need to replace the runner plate, and the next test run can continue.

[0104] In step 632, it is determined whether to replace the runner plate to continue engine testing. For example, if the test was stopped midway due to an anomaly detected in step 612 and it was determined in step 631 that the runner plate was normal, testing can continue with the current engine configuration in step 634. In another example, if the test was stopped midway due to an anomaly detected in step 612 and it was determined in step 631 that the runner plate was faulty, or the test of the current engine configuration has been successfully completed, then in step 632 it is determined whether there are other runner plates to be tested. If there are other runner plates to be tested, then the runner plate is replaced in step 633 and testing of the reinstalled engine is carried out in step 634 (returning to step 610). In a preferred embodiment, runner plate replacement can be performed in pairs to ensure weight moment matching.

[0105] If the entire test course (as determined in step 632) has been completed for all components (flow channels), then method 600 ends.

[0106] By executing the process of Method 600, qualified runner plates can be selected for use in actual engines. Furthermore, the condition of the runner plates under different test conditions can be obtained, and this information can be used for performance analysis and design / manufacturing improvements of composite material runner plates.

[0107] Figure 7 This is a block diagram of a composite material flow channel plate test monitoring device according to an embodiment of the present invention. The monitoring device may include a test control device 701, a vibration sensor 702, a vibration treatment device 704, a non-destructive testing device 706, a condition judgment device 708, etc.

[0108] The test run control device 701 can control the engine test run process, such as starting or stopping the engine test run, setting engine test run parameters, and collecting engine test run data. The engine may include a fan disc and a bearing housing that serves as the fulcrum for the fan disc. Multiple composite material flow channel plates are mounted on the fan disc. The fan disc is fixed on a rotating shaft supported by the bearing housing and rotates with the rotating shaft during the engine test run.

[0109] Vibration sensor 702 may be located on the bearing housing, for example near the shaft support point (e.g., the bearing) on ​​the bearing housing, for monitoring bearing support vibration during engine testing. Vibration sensor 702 may include an acceleration sensor, a velocity sensor, a displacement sensor, etc.

[0110] The vibration processing device 704 can receive signals detected by various vibration sensors 702 and determine whether the fulcrum vibration is abnormal. For example, if the vibration amplitude of the fulcrum is within the corresponding amplitude threshold range for the corresponding rotational speed, the vibration processing device 704 determines that the fulcrum vibration is normal; or if the vibration amplitude of the fulcrum exceeds the corresponding amplitude threshold range for the corresponding rotational speed, the vibration processing device 704 determines that the fulcrum vibration is abnormal.

[0111] In the event of abnormal fulcrum vibration, the engine test run can be stopped via the test run control device 701. The test run control device 701 can also determine the highest speed achieved during the engine test run. Subsequently, the non-destructive testing device 706 can perform non-destructive testing on the flow channel plate to obtain its non-destructive testing status. As an example and not a limitation, the non-destructive testing equipment may include portable ultrasonic A-scanning equipment, liquid penetrant testing equipment, etc.

[0112] The state determination device 708 compares the non-destructive testing state of the flow channel plate with a reference state to determine whether the flow channel plate is in a normal state. If the non-destructive testing state of the flow channel plate is better than or equal to the reference state, the flow channel plate is determined to be in a normal state; otherwise, the flow channel plate is determined to be in an abnormal state. In one example, the reference state can be an acceptable defect range, such as no defects, the presence of point defects, or the presence of line defects. In another example, the reference state can be a reference defect state corresponding to the highest rotational speed achieved.

[0113] Figure 7 The monitoring device shown can be connected with Figure 1-6 The described embodiments are implemented in combination. The test control device 701, vibration treatment device 704, and state judgment device 708 can be implemented separately or together, for example, using devices such as processors, controllers, computers, servers, and integrated circuits.

[0114] This invention provides a test monitoring method for composite material runner plates. Monitoring the runner plate during engine testing allows for timely acquisition of its operational status, preventing uncontrollable risks to the overall engine test due to abnormal conditions. Simultaneously, it provides non-destructive data on the runner plate during engine testing, offering reliable test data support for subsequent airworthiness certification.

[0115] The composite material runner plate commissioning monitoring method, static test, and rotation test provided in this paper can be implemented individually or in combination in any way. For example, according to one embodiment of the present invention, the composite material runner plate commissioning monitoring method of the present invention can be comprehensively utilized. First, the composite material runner plate is screened to determine benchmark parts, strength test parts, and mounting parts. Then, the mounting parts are matched to ensure that the imbalance is minimized, and static tensile tests and rotation tests can be carried out on the strength test parts to obtain the strength evaluation criteria of the composite material runner plate. Then, the state of the composite material runner plate can be monitored from three aspects: the vibration of the support points near the runner plate during commissioning, the visual and magnifying glass inspection after commissioning, and the non-destructive inspection after commissioning. Finally, the operating state of the runner plate is comprehensively judged to give a conclusion on whether to continue commissioning. Through the above method, the commissioning risk of composite material runner plates can be effectively controlled, supporting the smooth completion of commissioning tests.

[0116] The various steps and modules of the methods and apparatus described above can be implemented in hardware, software, or a combination thereof. If implemented in hardware, the various illustrative steps, modules, and circuits described in connection with this disclosure can be implemented or executed using a general-purpose processor, digital signal processor (DSP), application-specific integrated circuit (ASIC), field-programmable gate array (FPGA), or other programmable logic components, hardware components, or any combination thereof. A general-purpose processor can be a processor, microprocessor, controller, microcontroller, or state machine, etc. If implemented in software, the various illustrative steps and modules described in connection with this disclosure can be stored as one or more instructions or codes on a computer-readable medium or transmitted. Software modules implementing the various operations of this disclosure can reside in a storage medium, such as RAM, flash memory, ROM, EPROM, EEPROM, registers, hard disk, removable disk, CD-ROM, cloud storage, etc. The storage medium can be coupled to a processor so that the processor can read and write information from / to the storage medium and execute corresponding program modules to implement the various steps of this disclosure. Moreover, software-based embodiments can be uploaded, downloaded, or remotely accessed through appropriate communication means. Such appropriate means of communication include, for example, the Internet, the World Wide Web, intranets, software applications, cables (including fiber optic cables), magnetic communication, electromagnetic communication (including RF, microwave and infrared communication), electronic communication, or other such means of communication.

[0117] The numerical values ​​given in the various embodiments are merely examples and are not intended to limit the scope of the invention. Furthermore, as a whole, there are other components or steps not listed in the claims or specification of this invention. Moreover, a single name for a component does not preclude other names for that component.

[0118] It should also be noted that these embodiments may be described as processes depicted as flowcharts, flow diagrams, structure diagrams, or block diagrams. Although a flowchart may describe the operations as a sequential process, many of these operations can be executed in parallel or concurrently. Furthermore, the order of these operations can be rearranged.

[0119] The disclosed methods, apparatuses, and systems should not be limited in any way. Rather, this disclosure covers all novel and non-obvious features and aspects of the various disclosed embodiments (individually and in various combinations and sub-combinations of each other). The disclosed methods, apparatuses, and systems are not limited to any particular aspect or feature or combination thereof, and no disclosed embodiment is required to have any one or more specific advantages or to solve any particular or all technical problems.

[0120] This invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other modifications based on the teachings of this invention without departing from the spirit and scope of the claims. All of these modifications are within the scope of protection of this invention.

Claims

1. A method for monitoring the commissioning of a composite material flow channel plate, characterized in that, include: Non-destructive testing was performed on multiple composite flow channel plates made of the same material and with the same specifications to obtain non-destructive testing signals; Based on the non-destructive testing signals, a qualified first flow channel plate, a second flow channel plate, and / or a third flow channel plate are determined. The first flow channel plate is used to perform engine testing, the second flow channel plate is used for static tensile testing, and / or the third flow channel plate is used for rotational testing. The non-destructive testing signal of the first flow channel plate is superior to or equal to the non-destructive testing signals of the second and third flow channel plates. The engine includes a fan disc and a bearing housing that serves as the fulcrum of the fan disc. The first flow channel plate is mounted on the fan disc. The fan disc is fixed on a rotating shaft supported by the bearing housing and rotates with the rotating shaft during engine testing. During the engine test run, the vibration of the pivot point, detected by a vibration sensor mounted on the bearing housing, is monitored. If the vibration of the fulcrum is abnormal, the engine test run should be stopped. If the engine test is stopped due to abnormal vibration of the pivot point, the highest speed achieved during the engine test is determined. The first flow channel plate was subjected to non-destructive testing after the test run to obtain the non-destructive testing status of the first flow channel plate. as well as The non-destructive testing status of the first flow channel plate is compared with the reference status corresponding to the highest rotational speed to determine whether the first flow channel plate is in normal condition. The reference state is determined based on the non-destructive testing state at various converted speeds obtained from the static tensile test of the second flow channel plate, and / or the non-destructive testing state at various speeds obtained from the rotation test of the third flow channel plate.

2. The method for monitoring the test run of composite material flow channel plates as described in claim 1, characterized in that, Also includes: If the vibration amplitude of the fulcrum is within the corresponding amplitude threshold range of the corresponding rotational speed, then the vibration of the fulcrum is determined to be normal. or If the vibration amplitude of the fulcrum exceeds the corresponding amplitude threshold range of the corresponding rotational speed, then the vibration of the fulcrum is determined to be abnormal.

3. The method for monitoring the test run of composite material flow channel plates as described in claim 1, characterized in that, The permissible defect range for the composite material flow channel plate includes no defects, the presence of point defects, or the presence of linear defects. If the non-destructive testing indicates the presence of cracks and / or area defects, then the condition of the first flow channel plate is determined to be abnormal.

4. The method for monitoring the test run of composite material flow channel plates as described in claim 1, characterized in that, Also includes: If the non-destructive testing status of the first flow channel plate is better than or equal to the reference status corresponding to the highest rotational speed, then the status of the first flow channel plate is determined to be normal. or If the non-destructive testing status of the first flow channel plate is worse than the reference status corresponding to the highest rotational speed, then the status of the first flow channel plate is determined to be abnormal.

5. The method for monitoring the test run of composite material flow channel plates as described in claim 1, characterized in that, The reference states include the rotational speed and corresponding non-destructive testing state when the initial crack appears, and the rotational speed and corresponding non-destructive testing state when the load-bearing capacity is lost.

6. The method for monitoring the test run of composite material flow channel plates as described in claim 1, characterized in that, The non-destructive testing status includes one or more of the following: defect type, defect size, and defect location.

7. A test monitoring device for composite material flow channel plates, characterized in that, include: Non-destructive testing equipment is used to perform non-destructive testing on multiple composite material flow channel plates made of the same material and having the same specifications to obtain non-destructive testing signals; A status determination device determines qualified first flow channel plate, second flow channel plate and / or third flow channel plate based on the non-destructive testing signal. The first flow channel plate is used to perform engine test process, the second flow channel plate is used for static tensile test and / or the third flow channel plate is used for rotation test. The non-destructive testing signal of the first flow channel plate is better than or equal to the non-destructive testing signal of the second flow channel plate and the third flow channel plate. A vibration sensor is installed on a bearing housing in the engine, the bearing housing serving as a fulcrum for a fan disc, on which the first flow channel plate is mounted, the fan disc being fixed to a rotating shaft supported by the bearing housing and rotating with the rotating shaft during engine testing, the vibration sensor being used to detect vibration at the fulcrum during engine testing; A test run control device, wherein if the pivot point vibration is abnormal, the test run control device stops the engine test run process; wherein if the engine test run process is stopped due to the abnormal pivot point vibration, the test run control device determines the highest speed achieved during the engine test run process. The non-destructive testing device performs non-destructive testing on the first flow channel plate after the test run to obtain the non-destructive testing status of the first flow channel plate. The state determination device compares the non-destructive testing state of the first flow channel plate with the reference state corresponding to the highest rotational speed to determine whether the state of the first flow channel plate is normal. The reference state is determined based on the non-destructive testing state at various converted speeds obtained from the static tensile test of the second flow channel plate, and / or the non-destructive testing state at various speeds obtained from the rotation test of the third flow channel plate.

8. The composite material flow channel plate test monitoring device as described in claim 7, characterized in that, Also includes: The vibration processing device determines that the vibration of the fulcrum is normal if the vibration amplitude of the fulcrum is within the corresponding amplitude threshold range of the corresponding rotational speed; or determines that the vibration of the fulcrum is abnormal if the vibration amplitude of the fulcrum exceeds the corresponding amplitude threshold range of the corresponding rotational speed.

9. The composite material flow channel plate test monitoring device as described in claim 7, characterized in that, The permissible defect range for the composite material flow channel plate includes no defects, the presence of point defects, or the presence of linear defects. If the non-destructive testing status indicates the presence of cracks and / or area defects, the status determination device determines that the first flow channel plate is in an abnormal state.

10. The composite material flow channel plate test monitoring device as described in claim 7, characterized in that: If the non-destructive testing status of the first flow channel plate is better than or equal to the reference status corresponding to the highest rotational speed, then the status judgment device determines that the status of the first flow channel plate is normal. or If the non-destructive testing status of the first flow channel plate is worse than the reference status corresponding to the highest rotational speed, the status determination device determines that the status of the first flow channel plate is abnormal.

11. The composite material flow channel plate test monitoring device as described in claim 7, characterized in that, The reference states include the rotational speed and corresponding non-destructive testing state when the initial crack appears, and the rotational speed and corresponding non-destructive testing state when the load-bearing capacity is lost.

12. The composite material flow channel plate test monitoring device as described in claim 7, characterized in that, The non-destructive testing status includes one or more of the following: defect type, defect size, and defect location.

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