A method of manufacturing a tps unit

Abstract

This invention discloses a manufacturing method for a TPS unit, relating to the technical field of TPS unit manufacturing methods, including the following steps: S1: Calculate a scaled-down model based on the basic type and structural indicators of the TPS unit, and provide a three-dimensional model; S2: Determine the rotor scheme after meeting the requirements; S3: Determine the fan and turbine schemes; S4: Determine the lubrication and sealing schemes; S5: Summarize the determined rotor scheme, fan and turbine scheme, and lubrication and sealing scheme into a performance component design; S6: Put the designed TPS unit into production. This method can provide the ability to develop and manufacture different models of TPS units according to different test requirements, greatly improving the progress of TPS unit development and manufacturing.

Description

Technical Field

[0001] This invention relates to the technical field of manufacturing methods for TPS units, specifically to a manufacturing method for a TPS unit. Background Technology

[0002] TPS is a new type of power plant simulation unit with a power density that can reach 8 to 10 times that of an electric motor. It is suitable for accurate power simulation and flow field simulation of aircraft equipped with turbofan engines. It is an essential test equipment in the aircraft development process. Due to the different flight sizes and flight requirements, different models and wind power TPS units are needed. However, the existing technology lacks a manufacturing method for TPS units from research and development to production. Summary of the Invention

[0003] The purpose of this invention is to address the shortcomings of existing technologies by providing a method for manufacturing a TPS unit.

[0004] Includes the following steps:

[0005] S1: Calculate a scaled-down model based on the basic form and structural parameters of the TPS unit to form the initial aerodynamic flow path. Input aerodynamic parameters to form the aerodynamic design of the rotor system.

[0006] The aerodynamic design of the rotor system includes:

[0007] Fan and turbine aerodynamic profiles,

[0008] Aerodynamic load, axial force and power,

[0009] 3D models of the fan and turbine;

[0010] S2: Estimate the spindle diameter by combining aerodynamic load, axial force and power, design the rotor system support, calculate the critical speed by combining the three-dimensional model of the fan and turbine with the rotor system support design, determine the rotor scheme after meeting the requirements, and give a vibration verification report.

[0011] S3: Combine the aerodynamic profiles of the fan and turbine, aerodynamic loads, axial forces and power, and the three-dimensional models of the fan and turbine to check the rotor strength. Once the requirements are met, the fan and turbine scheme will be determined.

[0012] S4: Estimate the bearing heat generation and lubricating oil quantity based on the bearing type and operating requirements. Design the lubrication system configuration based on the bearing heat generation and lubricating oil quantity. Further design the lubrication system and small air passage. After meeting the requirements, determine the lubrication and sealing scheme and provide a lubrication system design report.

[0013] S5: Based on the determined rotor scheme, fan and turbine scheme, and lubrication and sealing scheme, a performance component design is formed.

[0014] S6: Design structural components for the structure designed for performance components to form a complete TPS unit, and put the completed TPS unit into production.

[0015] Furthermore, after estimating the spindle diameter in step S2, bearing selection calculations are performed. After selecting the bearing, the selected bearing type is sent to step S4 for preliminary estimation of bearing heat generation and lubricating oil.

[0016] Furthermore, after the rotor scheme is determined in step S2, the selected bearing is manufactured.

[0017] Furthermore, after completing the structural component design, the strength of the casing, bracket, and directly connected parts is checked. After the check is completed, the drive structure design and check report are completed. The aerodynamic design report is obtained by calculating the check report, fan and turbine data.

[0018] Furthermore, structural component design includes the selection of electrical components, standard parts, volute design, piping system design, casing design, bearing housing design, and adjustment mechanism design.

[0019] Furthermore, the selection of standard parts includes fastener selection calculation, O-ring selection calculation, and spring selection calculation.

[0020] Furthermore, after completing the structural component design, an interface coordination diagram is created.

[0021] Furthermore, the interface coordination diagram includes an electrical interface coordination diagram and a structural interface coordination diagram.

[0022] Furthermore, product models and drawings are prepared by combining performance component design and structural component design.

[0023] Furthermore, the dimensional chains of the model and drawings are calculated, and the tolerances in the product model and drawings are adjusted.

[0024] The advantages of this invention compared to the prior art are:

[0025] This solution first calculates a scaled-down model based on the basic TPS unit type and structural indicators. Then, it tests and confirms the performance structures (fan and turbine schemes, rotor schemes, lubrication and sealing schemes) in the TPS unit. Finally, it designs structural components based on the performance component design to form a complete TPS unit for production. Attached Figure Description

[0026] Figure 1 This is a flowchart of the manufacturing method for a TPS unit. Detailed Implementation

[0027] Combined with appendix Figure 1As shown, a method for manufacturing a TPS unit includes the following steps:

[0028] S1: Calculate a scaled-down model based on the basic form and structural parameters of the TPS unit to form the initial aerodynamic flow path. Input aerodynamic parameters to form the aerodynamic design of the rotor system.

[0029] The aerodynamic design of the rotor system includes:

[0030] Fan and turbine aerodynamic profiles,

[0031] Aerodynamic load, axial force and power,

[0032] 3D models of the fan and turbine;

[0033] S2: Estimate the spindle diameter by combining aerodynamic load, axial force and power, design the rotor system support, calculate the critical speed by combining the three-dimensional model of the fan and turbine with the rotor system support design, determine the rotor scheme after meeting the requirements, and give a vibration verification report.

[0034] S3: Combining the aerodynamic profiles of the fan and turbine; aerodynamic loads, axial forces and power; and three-dimensional models of the fan and turbine to check the rotor strength, and determine the fan and turbine scheme after meeting the requirements;

[0035] S4: Based on the bearing type and operating requirements, estimate the bearing heat generation and lubricating oil volume in advance. Based on the preliminary estimate of bearing heat generation and lubricating oil volume, design the lubrication system configuration. Further design the lubrication system and small air passage. After meeting the requirements, determine the lubrication and sealing scheme and provide a lubrication system design report.

[0036] S5: Based on the determined rotor scheme, fan and turbine scheme, and lubrication and sealing scheme, a performance component design is formed.

[0037] S6: Design structural components for the structure designed for performance components to form a complete TPS unit, and put the completed TPS unit into production.

[0038] Preferably, after estimating the spindle diameter in step S2, the bearing selection calculation is performed. After the bearing selection is completed, the bearing is sent to step S4 for preliminary estimation of bearing heat generation and lubricating oil based on the selected bearing type.

[0039] Preferably, the selected bearing is manufactured after the rotor scheme is determined in step S2.

[0040] Preferably, after the structural component design is completed, the strength of the casing, bracket and direct parts is checked. After the check is completed, the drive structure design and check report are completed. The aerodynamic design report is obtained by calculating the check report, fan and turbine data.

[0041] Preferably, the structural component design includes the selection of electrical components, the selection of standard components, the design of the volute housing, the design of the piping system, the design of the casing, the design of the bearing housing, and the design of the adjustment links.

[0042] Preferably, the selection of standard parts includes fastener selection calculation, O-ring selection calculation, and spring selection calculation.

[0043] Preferably, an interface coordination diagram is created.

[0044] Preferably, the interface coordination diagram includes an electrical interface coordination diagram and a structural interface coordination diagram.

[0045] Preferably, product models and drawings are prepared by combining performance component design and structural component design.

[0046] Preferably, the dimensional chains of the model and drawings are calculated, and the tolerances in the product model and drawings are adjusted.

[0047] Fan development requirements:

[0048] Perform structural strength calculations on fan blades, taking into account centrifugal force, aerodynamic force and fatigue performance of the blades, and provide the safety factor and service life of the turbine blades, with a safety factor ≥ 1.5.

[0049] Fan blade alignment:

[0050] This project used the finite element analysis method to verify the strength of stainless steel fan blades and titanium alloy fan blades respectively.

[0051] During the analysis, the centrifugal load was calculated based on a maximum speed of 47,000 rpm, and an angular velocity of 4,920 rad / s along the Z-axis was applied to the fan rotor finite element model. The aerodynamic load and temperature load were obtained from the fan aerodynamic calculation and applied to the fan finite element model. The location of the maximum pressure was at the leading edge of the fan blade tip, with a pressure value of 245.77 kPa; the location of the maximum temperature was at the trailing edge of the fan blade tip, with a temperature value of 124.17 °C.

[0052] (1) When the stainless steel fan rotor operates at the maximum speed of 47,000 rpm, the maximum equivalent stress of the rotor is 789.9 MPa, located in the middle of the blade root, and the material yield strength is 1180 MPa.

[0053] (2) TC4 titanium alloy fan blades have a maximum equivalent stress of 450.7 MPa, a material yield strength of 736 MPa, and a safety factor of 1.63; TC11 fan blades have a maximum equivalent stress of 460.8 MPa and a yield strength of 920 MPa.

[0054] Turbine structural strength calculation

[0055] Turbine development requirements:

[0056] Perform structural strength calculations on turbine blades, considering centrifugal force, aerodynamic forces, and fatigue performance. Provide the safety factor and service life of the turbine blades, with a required safety factor ≥ 2.

[0057] The fan rotor machining process requires multiple inspections before proceeding to the next step. The general machining and inspection process is as follows: material re-inspection – bladed disk rough machining – bladed disk fine machining – dye penetrant testing – blade machining – blade frequency measurement – ​​dye penetrant testing – blade polishing – blade frequency measurement – ​​blade shot peening treatment – ​​blade frequency measurement – ​​rotor dynamic balancing treatment.

[0058] Turbo status:

[0059] This project used the finite element analysis method to verify the strength of the turbine blades.

[0060] The centrifugal load on the turbine blade is calculated based on a maximum speed of 47,000 rpm, and an angular velocity of 4,920 rad / s is applied to the turbine blade along the Z-axis. The aerodynamic and temperature loads are obtained from fan aerodynamic calculations. The maximum pressure is located at the leading edge of the turbine blade tip, with a pressure value of 772.86 kPa. The lowest temperature is located at the leading edge of the turbine blade tip, with a temperature value of -85.2℃. The highest temperature is located at the middle of the blade back and root, with a temperature value of -1.4℃.

[0061] When the turbine rotor operates at its maximum speed of 47,000 rpm, the maximum equivalent stress of the rotor is 126.6 MPa, and the material yield strength is 370.3 MPa.

[0062] Support system structural strength calculation

[0063] Research and development requirements:

[0064] Structural strength calculations were performed on the support system, applying thrust, gravity, and acceleration loads, with a safety factor ≥ 3.

[0065] Status of achievement:

[0066] This project used the finite element analysis method to verify the strength of the TPS support system.

[0067] During the analysis, thrust, gravity, and acceleration loads in all directions were applied to the whole machine model (loads are shown in Table 1) to analyze deformation and stress state. The support system (hanger) was regarded as a substructure and was modeled in detail. At the same time, interface contact was applied according to the actual assembly state to obtain the deformation, stress distribution, and contact state of the support structure under different loads.

[0068]

[0069] Studies have shown that

[0070] (1) The maximum stress of the TPS support system is located in the area of ​​the connecting bolts;

[0071] (2) Maximum stress and safety margin of the supporting structure under all-directional overload.

[0072]

[0073] Before unit assembly, a pressure test was conducted on the fan housing at a pressure of 5 MPa. Test procedure:

[0074] A. Record the outer diameter of the fan housing at three different locations;

[0075] B. Based on the given diagram, install the virtual turbine distributor and the rear cover of the housing inside the housing, and fix the hanger cover;

[0076] C. Maintain this pressure for 5 minutes;

[0077] D. No obvious deformation is acceptable, i.e., the diameter change is less than 0.03mm.

[0078] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, features defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0079] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0080] In the description of this invention, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0081] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A method for manufacturing a TPS unit, characterized in that, Includes the following steps: S1: Calculate a scaled-down model based on the basic form and structural parameters of the TPS unit to form the initial aerodynamic flow path. Input aerodynamic parameters to form the aerodynamic design of the rotor system. The aerodynamic design of the rotor system includes: Fan and turbine aerodynamic profiles, Aerodynamic load, axial force and power, 3D models of the fan and turbine; S2: Estimate the spindle diameter by combining aerodynamic load, axial force and power, design the rotor system support, calculate the critical speed by combining the three-dimensional model of the fan and turbine with the rotor system support design, determine the rotor scheme after meeting the requirements, and give a vibration verification report. S3: Combine the aerodynamic profiles of the fan and turbine, aerodynamic loads, axial forces and power, and the three-dimensional models of the fan and turbine to check the rotor strength. Once the requirements are met, the fan and turbine scheme will be determined. S4: Estimate the bearing heat generation and lubricating oil quantity based on the bearing type and operating requirements. Design the lubrication system configuration based on the estimated bearing heat generation and lubricating oil quantity. Further design the lubrication system and small air passage. After meeting the requirements, determine the lubrication and sealing scheme and provide a lubrication system design report. S5: Based on the determined rotor scheme, fan and turbine scheme, and lubrication and sealing scheme, a performance component design is formed; S6: Design structural components for the performance components to form a complete TPS unit, and put the completed TPS unit into production. The structural component design includes selection of electrical components, selection of standard components, design of volute housing, design of piping system, design of casing, design of bearing housing, and design of adjustment links; S7: After completing the structural component design, the strength of the casing, bracket and direct parts is checked. After the check is completed, the drive structure design and check report is generated. The aerodynamic design report is obtained by calculating the check report, fan and turbine data.

2. The manufacturing method of a TPS unit according to claim 1, characterized in that, After estimating the spindle diameter in step S2, the bearing selection calculation is performed. After the bearing selection is completed, the selected bearing type is sent to step S4 for preliminary estimation of bearing heat generation and lubricating oil.

3. The manufacturing method of a TPS unit according to claim 2, characterized in that, After the rotor design is determined in step S2, the selected bearing is manufactured.

4. The manufacturing method of a TPS unit according to claim 1, characterized in that, The selection of standard parts includes fastener selection calculation, O-ring selection calculation, and spring selection calculation.

5. A method for manufacturing a TPS unit according to claim 2, characterized in that, After completing the structural component design, create an interface coordination diagram.

6. A method for manufacturing a TPS unit according to claim 5, characterized in that, The interface coordination diagram includes an electrical interface coordination diagram and a structural interface coordination diagram.

7. A method for manufacturing a TPS unit according to claim 6, characterized in that, Product models and drawings are prepared by combining performance component design and structural component design.

8. A method for manufacturing a TPS unit according to claim 7, characterized in that, Calculate the dimensional chains of the model and drawings, and adjust the tolerances in the product model and drawings.

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