A simulated electrical load system for airborne testing of aero-engines

Abstract

This invention belongs to the field of aircraft flight testing and relates to a simulated electrical load system for airborne testing of aero-engines. It includes: an air inlet, a compressor, an electric motor, multiple one-way valves, multiple pipes, an adjustable flow port, a resistance wire, an exhaust port, a display controller, and matching cables. The air inlet is connected to the exhaust port via a first branch, which includes a pipe and a one-way valve. The air inlet is also connected to the exhaust port via a second branch, which includes the compressor, the electric motor, and the one-way valve. The compressor inlet is connected to the air inlet, and the compressor outlet is connected to the interior of the exhaust port via a pipe. A one-way valve is installed on the pipe connecting the compressor and the interior of the exhaust port. An adjustable flow port is installed on the pipe inside the exhaust port, and a resistance wire is installed inside the pipe inside the exhaust port. The output terminal of the electric motor is connected to the drive shaft of the compressor. The display controller is connected to the control terminal of the electric motor via matching cables for controlling the electric motor.

Description

Technical Field

[0001] This invention belongs to the field of aircraft flight testing and relates to a simulated electrical load system for airborne testing of aero-engines. It can realize the extraction and consumption of electrical energy of aero-engines during flight testing, simulate the electrical load of aircraft under different operating conditions, and is used for aero-engine performance evaluation. Background Technology

[0002] In aero-engine flight testing, electrical load systems are typically used to extract and consume power from the engine's generator, enabling generator loading and testing. Currently, electrical load systems used in aero-engine flight testing usually employ resistance heating to consume power, converting electrical energy into the internal energy of the resistance wire, using air or water as the heat dissipation medium. Based on the final cooling method, they are classified as air-cooled, evaporative, etc. However, current electrical load systems are limited by heat dissipation area and medium capacity, typically allowing a maximum load power of only around 100–200 kW, which cannot meet the testing and verification requirements of high-power generators for new engines. Summary of the Invention

[0003] Objective: This invention proposes a simulated electrical load system for airborne testing of aero-engines. The system can be installed on an airborne test rig for aero-engines. It draws electrical energy generated by the aero-engine's generator and converts it into thermal, pressure, and mechanical energy of the air using a combination of principles such as an electric compressor and air-cooled resistance wire. The energy is then consumed through air cooling and exhaust, simulating the electrical load of the aero-engine and thus providing relevant testing capabilities. Compared to traditional airborne electrical load systems for aero-engines, the system of this invention, using a combination primarily based on an electric compressor for energy conversion and consumption, overcomes the limitations of traditional systems in terms of heat dissipation area and medium capacity, providing greater energy consumption capacity in a smaller volume.

[0004] Technical solution:

[0005] A simulated electrical load system for airborne testing of an aero-engine includes: an air inlet 1, a compressor 2, an electric motor 3, multiple one-way valves 4, multiple pipes 5, an adjustable flow port 6, a resistance wire 7, an exhaust port 8, a display controller 9, and matching cables 10.

[0006] The air inlet 1 is connected to the exhaust port 8 through a first branch, which includes a pipe and a one-way valve 4. The air inlet 1 is connected to the exhaust port 8 through a second branch, which includes a compressor 2, a motor 3, and a one-way valve 4. The inlet of the compressor 2 is connected to the air inlet 1, and the outlet of the compressor 2 is connected to the inside of the exhaust port 8 through a pipe. A one-way valve 4 is installed on the pipe connecting the compressor 2 and the inside of the exhaust port 8. An adjustable flow port 6 is installed on the pipe inside the exhaust port 8. A resistance wire 7 is installed in the pipe inside the exhaust port 8. The output end of the motor 3 is connected to the drive shaft of the compressor 2. The display controller 9 is connected to the control end of the motor 3 through a matching cable 10 and is used to control the motor 3.

[0007] Furthermore, the drive motor and display controller 9 are electrically connected to the adjustable port 6 via a matching cable 10 to control the opening degree of the adjustable port 6.

[0008] Furthermore, the air inlet 1 is the source of the energy conversion medium for the electrical load, and outside air enters the system pipeline through the air inlet 1.

[0009] Furthermore, the compressor 2 is the main component for electrical energy conversion. The compressor 2 is driven by an electric motor to compress the air entering from the air inlet 1, thereby increasing its pressure and temperature.

[0010] Furthermore, the electric motor 3 drives the compressor 2, which consumes electrical energy and converts it into mechanical energy to rotate the compressor 2, thus realizing the consumption and conversion of energy.

[0011] Furthermore, the one-way valve 4 is a core component for controlling the airflow direction within the system pipeline 5. When multiple compressors are connected in parallel, the opening and closing of the one-way valve 4 is automatically controlled by pressure to ensure the correct airflow within the system.

[0012] Furthermore, pipe 5 serves as a channel for the flow of air, and can also withstand changes in the temperature and pressure of the air during system operation.

[0013] Furthermore, the adjustable orifice 6 provides a reasonable outlet pressure for the compressor 2 by throttling the air medium, ensuring that it is in normal working condition. At the same time, the orifice 6 also plays a role in energy conversion. When the high-temperature and high-pressure air passes through the orifice, the pressure decreases while the temperature increases due to friction with the wall, converting pressure energy into heat energy, mechanical energy, and residual kinetic energy of the air. The orifice 6 changes its working characteristics through electronic control, thereby adjusting the working state of the system. The mechanical structure of the orifice 6 is located inside the exhaust port 8, and the orifice structure is cooled by the cold air in the outer pipe.

[0014] Furthermore, the resistance wire 7 is an auxiliary component for electrical energy conversion. Through the Joule heating effect, electrical energy is converted into heat energy of the resistance wire 7. The resistance wire 7 dissipates heat using air as a medium. The heat is replenished through the resistance wire 7, thereby achieving precise control of the load power of the engine 3.

[0015] Furthermore, exhaust port 8 is the outlet for the air medium within the system. Air that has been heated and has a certain kinetic energy after being converted by upstream energy is discharged into the atmosphere through the exhaust port. Display controller 9 is a device used for user interaction and system operation control. The controller completes the conversion, distribution, and control of the working status of each device by the electrical energy drawn from the aero-engine generator. At the same time, it provides users with a visual interface to acquire and control the system's working status. Matching cable 10 is used to transmit the electrical energy generated by the aero-engine generator and the control signals of each device.

[0016] Beneficial effects:

[0017] The system described in this invention utilizes a device primarily based on an electric compressor to compress, process, and discharge air as the working medium, thereby converting and consuming electrical energy to simulate the electrical load of an aero-engine. This system is used for airborne testing of aero-engines and can controllably convert and consume the high-power electrical energy generated by the generator according to the needs of the airborne test. This system has a simple structure, a wide range of adjustable performance, and is no longer limited by heat dissipation area or medium capacity, enabling it to achieve a stronger aircraft electrical load simulation capability than traditional methods within a smaller volume. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of a simulated electrical load system for airborne testing of an aero-engine according to the present invention;

[0019] The components include: 1. Air inlet; 2. Compressor; 3. Electric motor; 4. Check valve; 5. Pipeline; 6. Adjustable outlet; 7. Resistance wire; 8. Exhaust outlet; 9. Display controller; 10. Matching cables. Detailed Implementation

[0020] In practical applications, traditional electrical load systems primarily utilize the Joule heating effect to convert the electrical energy generated by the generator of an aero-engine into heat energy, using water (evaporative) or air (air-cooled) as the heat dissipation medium for continuous cooling, thus simulating the electrical load during aero-engine operation. This invention uses air as the medium, consuming the electrical energy generated by the tested aero-engine. An electric compressor compresses the medium, and a throttling device further converts the energy into the kinetic and thermal energy of the air for emission. This increases the air emission temperature and velocity, reduces system volume, and improves medium utilization efficiency. Currently, there are no mature application cases of simulated electrical load systems using electric compressors as the core energy conversion device in airborne tests of various aero-engines.

[0021] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] The features and illustrative embodiments of various aspects of the present invention will now be described in detail. Numerous specific details are set forth in the following detailed description to provide a thorough understanding of the invention. However, it will be apparent to those skilled in the art that the invention may be practiced without requiring some of these specific details. The following description of embodiments is merely intended to provide a better understanding of the invention by illustrating examples of the invention. The invention is by no means limited to any specific setups and methods set forth below, but covers any improvements, substitutions, and modifications to structures, methods, and devices without departing from the spirit of the invention. Well-known structures and techniques are not shown in the drawings and the following description to avoid unnecessarily obscuring the invention.

[0023] It should be noted that, unless otherwise specified, the embodiments of the present invention and the features thereof can be combined with each other, and the various embodiments can be referenced and cited in each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0024] Figure 1 This is a schematic diagram of a simulated electrical load system for airborne testing of an aero-engine, according to an example of the present invention.

[0025] like Figure 1 As shown, a simulated electrical load system for airborne testing of an aero-engine includes: an air inlet 1, a compressor 2, an electric motor 3, a one-way valve 4, a pipe 5, an adjustable flow port 6, a resistance wire 7, an exhaust port 8, a display controller 9, and matching cables 10.

[0026] The air inlet 1 is connected to the exhaust port 8 through a first branch, which includes a pipe and a one-way valve 4. The air inlet 1 is connected to the exhaust port 8 through a second branch, which includes a compressor 2, a motor 3, and a one-way valve 4. The inlet of the compressor 2 is connected to the air inlet 1, and the outlet of the compressor 2 is connected to the inside of the exhaust port 8 through a pipe. A one-way valve 4 is installed on the pipe connecting the compressor 2 and the inside of the exhaust port 8. An adjustable flow port 6 is installed on the pipe inside the exhaust port 8. A resistance wire 7 is installed in the pipe inside the exhaust port 8. The output end of the motor 3 is connected to the drive shaft of the compressor 2. The display controller 9 is connected to the control end of the motor 3 through a matching cable 10 and is used to control the motor 3.

[0027] There can be multiple second branches.

[0028] The air inlet 1 is installed on the outer surface of the aircraft, which is the airborne test platform for the aircraft engine, facing the aircraft's heading. During flight, air is forced into the system duct 5 by ramming. In some embodiments, an opening can also be made on the side of the aircraft, so that the system can allow air to enter the duct 5 by the suction of the compressor 2 and the ejection of the exhaust port 8 when the aircraft is parked on the ground or during flight.

[0029] The inlet of the compressor 2 is connected to the air inlet 1 through the pipe 5. The compressor 2 is driven by the electric motor 3 and compresses the air entering from the air inlet 1 to increase its pressure and temperature. In some embodiments, the power of the simulated electrical load of the system can be increased by combining multiple compressors 2 and electric motors 3 in parallel.

[0030] The electric motor 3 directly drives the compressor 2, and the operation of the electric motor 3 is controlled by the display controller 9. The electric motor can be a permanent magnet motor or an induction motor, and the power and operating characteristics of the electric motor are matched with those of the compressor 2.

[0031] One-way valve 4 is installed on the outlet pipeline of compressor 2. The one-way valve ensures the normal operation of the system logic. In particular, when multiple compressors are connected in parallel, the one-way valve ensures that one compressor will not affect the normal operation of other compressors and ensures that the medium in the system flows in the correct direction.

[0032] Pipe 5 is a conduit for the flow of air between various functional accessories within the system. Depending on functional requirements, different diameters and materials may be used in different sections of the pipe. In this embodiment, pipe 5 is double-layered when flowing through the adjustable outlet, with hot air flowing in the inner layer and cold air flowing in the outer layer. In some embodiments, the pipe routing and topology of pipe 5 need to be adjusted according to the system design and installation conditions.

[0033] The adjustable orifice 6 adjusts its throttling characteristics by electrically driving changes the local flow cross-sectional area. The adjustable orifice 6 will generate a temperature rise during use, requiring materials and components with good thermal conductivity and heat resistance. In this embodiment, the mechanical structure of the throttling orifice is located within the double-layer pipe 5, and the orifice structure is cooled by the cold air in the outer pipe. In some embodiments, to improve the heat dissipation efficiency of the orifice structure, the adjustable orifice structure encased in the outer cold air pipe may be equipped with heat dissipation fins.

[0034] The resistance wire 7 is installed inside the pipe 5, and is precisely loaded with relatively low power through the Joule heating effect. The heated resistance wire is then dissipated by a throttled high-speed airflow. The resistance wire 7 is insulated from the pipe 5. The resistance wire 7 is made of a high-resistance alloy material with high rigidity. In some embodiments, the resistance wire 7 can also be placed inside the outer cold airflow pipe to achieve better heat dissipation by increasing the temperature difference, which requires a relatively larger outer airflow.

[0035] Exhaust port 8 is the outlet of the air medium in the system. During implementation, a reasonable exhaust port location should be selected according to the characteristics of the aircraft platform to avoid hot airflow affecting the normal flight of the aircraft and the normal operation of other systems on board. In this embodiment, exhaust port 8 is double-layered, with the inner layer being high-temperature and high-speed exhaust and the outer layer being low-temperature and low-speed exhaust. The high-temperature and high-speed exhaust of the inner layer has a certain ejection effect on the exhaust of the outer layer and can increase the flow rate by increasing the pressure difference at the end of the outer layer pipeline.

[0036] The display controller 9 can comprehensively realize the conversion and distribution of electrical energy and the control of various devices within the system, while also providing a visual interface for users. Users can read the system's operating status and input control commands through the display controller interface. In some embodiments, the display controller can be divided into multiple devices, such as those based on functions like power conversion, power distribution, display, and control, enabling distributed installation on the aircraft platform.

[0037] The matching cable 9 is used to transmit electrical energy generated by the generator of the aircraft engine and control signals of various devices.

[0038] In summary, the core of this invention lies in using an electric compressor to compress air, and then converting the energy into the kinetic and thermal energy of the air through a throttling device before discharging it. This process consumes electrical energy generated by the aero-engine generator, simulating the electrical load of airborne equipment for aero-engine airborne testing. Compared to traditional air-cooled electrical load systems that use air as the medium, this invention improves medium utilization efficiency by increasing the air discharge temperature and velocity, achieving the simulation of high-power electrical loads within the same volume.

Claims

1. A simulated electrical load system for airborne testing of an aero-engine, characterized in that, include: Air inlet (1), compressor (2), electric motor (3), multiple check valves (4), multiple pipes (5), adjustable flow port (6), resistance wire (7), exhaust port (8), display controller (9), and matching cables (10), among which, The air inlet (1) is connected to the exhaust port (8) through the first branch, which includes a pipe and a one-way valve (4). The air inlet (1) is connected to the exhaust port (8) through the second branch, which includes a compressor (2), a motor (3), and a one-way valve (4). The inlet of the compressor (2) is connected to the air inlet (1), and the outlet of the compressor (2) is connected to the inside of the exhaust port (8) through a pipe. A one-way valve (4) is installed on the pipe connecting the compressor (2) and the inside of the exhaust port (8). An adjustable flow port (6) is installed on the pipe inside the exhaust port (8). A resistance wire (7) is installed in the pipe inside the exhaust port (8). The output end of the motor (3) is connected to the drive shaft of the compressor (2). The display controller (9) is connected to the control end of the motor (3) through a matching cable (10) to control the motor (3).

2. The simulated electrical load system for airborne testing of aero-engines according to claim 1, characterized in that, The drive motor and display controller (9) are electrically connected to the adjustable port (6) via a matching cable (10) to control the opening degree of the adjustable port (6).

3. The simulated electrical load system for airborne testing of aero-engines according to claim 1, characterized in that, The air inlet (1) is the source of the energy conversion medium for the electrical load. Outside air enters the system pipeline through the air inlet (1).

4. The simulated electrical load system for airborne testing of aero-engines according to claim 1, characterized in that, The compressor (2) is the main component for electrical energy conversion. The compressor (2) is driven by an electric motor to compress the air entering from the air inlet (1) and increase its pressure and temperature.

5. The simulated electrical load system for airborne testing of aero-engines according to claim 1, characterized in that, The electric motor (3) drives the compressor (2), and by consuming electrical energy, it converts it into mechanical energy for the compressor (2) to rotate, thus realizing the consumption and conversion of energy.

6. The simulated electrical load system for airborne testing of aero-engines according to claim 1, characterized in that, The one-way valve (4) is the core component for controlling the direction of air flow in the system pipeline (5). When multiple compressors are connected in parallel, the one-way valve (4) is automatically controlled by pressure to ensure the correct flow of air in the system.

7. The simulated electrical load system for airborne testing of aero-engines according to claim 1, characterized in that, Pipe (5) is a channel for the flow of air medium, and it can also withstand the changes in temperature and pressure of air medium during system operation.

8. The simulated electrical load system for airborne testing of aero-engines according to claim 1, characterized in that, The adjustable orifice (6) provides a reasonable outlet pressure for the compressor (2) by throttling the air medium, ensuring that it is in normal working condition. At the same time, the orifice (6) also plays a role in energy conversion. When the high-temperature and high-pressure air passes through the orifice, the pressure is reduced and the temperature is increased due to friction with the wall, converting pressure energy into heat energy, mechanical energy and residual kinetic energy of the air. The orifice (6) changes its working characteristics through electronic control to adjust the working state of the system. The mechanical structure of the orifice (6) is located inside the exhaust port (8), and the orifice structure is cooled by the cold air in the outer pipe.

9. The simulated electrical load system for airborne testing of aero-engines according to claim 1, characterized in that, The resistance wire (7) is an auxiliary component for electrical energy conversion. Through the Joule heating effect, electrical energy is converted into the heat energy of the resistance wire (7). The resistance wire (7) dissipates heat using air as a medium. The heat is replenished through the resistance wire (7) to achieve precise control of the load power of the engine (3).

10. The simulated electrical load system for airborne testing of aero-engines according to claim 1, characterized in that, The exhaust port (8) is the outlet of the air medium in the system. The air, which has been heated by the upstream energy conversion and has a certain kinetic energy, is discharged into the atmosphere through the exhaust port. The display controller (9) is a device for user interaction and system operation control. It converts, distributes, and controls the working status of various devices by drawing electrical energy from the aero-engine generator, and provides a visual interface for users to obtain and control the system's working status. The matching cable (10) is used to transmit electrical energy generated by the generator of the aircraft engine and control signals of various devices.

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