Environmental control liquid cooling system equivalent simulation test system and test method

Abstract

The invention belongs to an aviation aircraft test technology, and particularly relates to an equivalent simulation test system and test method for an environmental control liquid cooling system, an actual environmental control system is simulated through two aspects of flow resistance simulation and thermal simulation, an environmental control system test bed is constructed, and the test verification requirement of the environmental control system is met; the flow resistance simulation comprises two parts of liquid cooling equipment resistance simulation and liquid cooling pipeline resistance simulation, and the equipment thermal simulation comprises two parts of internal thermal load and external thermal load of the environmental control system. According to the equivalent simulation test technology and method for the environmental control liquid cooling system, the equipment resistance and the pipeline resistance are simulated in different modes, the equipment resistance with a complex flow channel can be accurately simulated, a pipe network structure with a simple flow channel and a complex connection form can be simplified, and on the premise that the resistance of the environmental control liquid cooling system is not affected, the test efficiency is improved. And the construction time and cost of the test bench are reduced.

Description

Technical Field

[0001] The present invention belongs to aviation vehicle test technology, and in particular relates to an environmental control liquid cooling system equivalent simulation test system and a test method. Background Art

[0002] Testing is an important part of aviation product design. In order to adapt to the rapid iteration of product design, more time-saving and efficient testing technology is needed. For test systems that use pipelines and various fluids to achieve environmental control and thermal management, existing testing technologies usually require the use of test pieces that are consistent with actual pipelines. Due to the high threshold of production technology and high manufacturing capacity requirements, the number of manufacturers with production capacity is limited, resulting in a long pipeline production and manufacturing cycle. In addition, actual aircraft product equipment has multiple complex parameters such as flow resistance and heat consumption. The cycle of producing complete and qualified finished equipment in the early stage of design is long, which makes it difficult to support early tests and subsequent design iterations, and seriously prolongs the test cycle. At the same time, the use of actual product pipelines and finished equipment to build a test bench will lead to problems such as large test bench footprint, complex wiring, and difficult maintenance. Under this background technology, for the test of aircraft environmental control liquid cooling system, the present invention proposes an equivalent simulation test technology and method for environmental control liquid cooling system. Summary of the invention

[0003] Purpose of the invention: In order to improve the test efficiency of the environmental control liquid cooling system and reduce the construction period and floor space of the test bench, a pipe network flow resistance simulation and equipment thermal simulation configuration are designed, and an equivalent simulation test technology and method for the environmental control liquid cooling system is provided.

[0004] Technical solution: In order to achieve the above-mentioned purpose, on the one hand, the present invention proposes an equivalent simulation test method for an environmental control liquid cooling system, which simulates the actual environmental control system through flow resistance simulation and thermal simulation, constructs an environmental control system test bench, and realizes the test verification requirements of the environmental control system; the flow resistance simulation includes two parts: liquid cooling equipment resistance simulation and liquid cooling pipeline resistance simulation, and the equipment thermal simulation includes two parts: internal heat load and external heat load of the environmental control system.

[0005] Furthermore, the resistance simulation of the liquid cooling equipment is simulated in the form of a finished product flow resistance simulation part, wherein the flow resistance simulation part mainly refers to a purely mechanical structural part that is consistent with the appearance and internal flow channel of the actual finished product equipment and may not contain electronic components.

[0006] Furthermore, the liquid cooling pipeline resistance simulation simulates the real pipeline resistance by combining regulating valves, pipe accessories, straight pipe sections and simulation calculation data. The simulation calculation data refers to the flow resistance data of the pipe section and the pipe network system calculated by the simulation software to construct the relationship between flow rate and pressure drop.

[0007] Furthermore, the regulating valve can achieve 0-90° stepless adjustment. The pipe accessories mainly include elbows, tees, crosses, reducers and other connectors. The straight pipe section refers to a whole section of pipe with a constant diameter and no other connectors in the middle.

[0008] Furthermore, the liquid cooling pipeline resistance simulation is divided into single pipe segment resistance simulation and multiple pipe segment resistance simulation, wherein the single pipe segment resistance simulation represents a method of simulating a real straight pipe segment at a corresponding position through a test bench straight pipe segment with a resistance simulation regulating valve, and the multiple pipe segment resistance simulation represents a method of simulating multiple interconnected real straight pipe segments through a test bench straight pipe segment with a resistance simulation regulating valve.

[0009] Furthermore, the internal heat load of the environmental control system refers to the total heat generated by electronic equipment that is directly connected to the environmental control liquid cooling system pipeline and directly dissipates heat through the environmental control liquid cooling system. The internal heat load is usually simulated by a series pipe heater so that the heater directly heats the environmental control liquid cooling medium.

[0010] Furthermore, the external heat load of the environmental control system refers to the total heat of the heat medium that is indirectly interconnected with the environmental control liquid condenser system and exchanges heat with the environmental control liquid cooling system through an independent multi-channel heat exchanger. The liquid cooling equipment resistance simulation component includes the above-mentioned independent multi-channel heat exchanger, and the external heat load is usually simulated by a wide-temperature and wide-flow cooling and heating integrated unit.

[0011] On the other hand, the present invention also proposes an equivalent simulation test system for an environmental control liquid cooling system, which is used to implement the above-mentioned equivalent simulation test method for an environmental control liquid cooling system, and the test system includes: a thermal simulation unit, a flow resistance simulation unit;

[0012] The thermal simulation unit also includes an internal heat load simulation module and an external heat load simulation module. The internal heat load simulation module uses a pipeline heater connected in series to the system pipe network to simulate the heat generated by the environmental control liquid-cooled electronic equipment; the external load simulation module uses a heating and cooling integrated unit, which is interconnected with the system pipe network through a heat exchanger to simulate the heat exchange state between the external system and the environmental control system;

[0013] The flow resistance simulation unit also includes a liquid cooling device flow resistance simulation module and a liquid cooling pipeline flow resistance simulation module.

[0014] Among them, the liquid cooling equipment flow resistance simulation module produces and manufactures structural parts that are consistent with the actual liquid cooling equipment radiator flow channel based on the three-dimensional digital model of the actual liquid cooling equipment. Under the premise of ensuring the accuracy of the flow resistance of the simulated parts, the structure and manufacturing difficulty of the liquid cooling equipment test pieces are simplified; the liquid cooling pipeline flow resistance simulation module simulates the actual liquid cooling pipeline network resistance through regular straight pipelines and regulating valves and other flow resistance simulation mechanisms, thereby reducing the complexity of the test system pipeline network, improving the adaptability of the test system, and facilitating modular construction.

[0015] Furthermore, the external system includes a fuel system, an external atmosphere system, external solar radiation, etc.

[0016] Technical effects: (1) The equivalent simulation test technology and method of the environmental control liquid cooling system proposed in the present invention simulates the equipment and pipeline resistance in different ways, which can not only accurately simulate the equipment resistance with complex flow channels, but also simplify the pipeline structure with simple flow channels but complex connection forms. Under the premise of not affecting the resistance of the environmental control liquid cooling system, the construction time and cost of the test bench are shortened.

[0017] (2) The equivalent simulation test technology and method of the environmental control liquid cooling system proposed in the present invention can simplify the pipe network structure, save the space occupied by the test bench, and realize the modular design of the test bench. At the same time, the pipe network resistance can be adjusted, which can improve the reusability of the test bench and ensure the rapid iterative verification of the environmental control system.

[0018] (3) The pipeline resistance simulation configuration proposed in the present invention includes a variety of resistance simulation situations, which can be flexibly combined, have strong applicability, and ensure the accuracy of resistance simulation.

[0019] (4) The equivalent simulation test technology and method of the environmental control liquid cooling system proposed in the present invention simulates the internal heat load by connecting a series of tubular heaters, and directly adds heat to the environmental control liquid cooling medium without the need for secondary heat exchange, thereby improving the heat exchange efficiency, accelerating the heating response time, and saving energy and reducing emissions.

[0020] (5) The equivalent simulation test technology and method of the environmental control liquid cooling system proposed in the present invention simulates the external heat load through a wide-temperature and wide-flow refrigeration and heating integrated unit, which can simulate the external heat load under different working conditions, improve the use range of the test bench, and realize dynamic adjustment of the external heat load, realize rapid switching of working conditions, and improve test efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is the principle diagram of the equivalent simulation test technology and method of the environmental control liquid cooling system;

[0022] Figure 2 Flow chart for setting up a test bench for using the equivalent simulation test technology and method of the environmental control liquid cooling system;

[0023] Figure 3 This is the schematic diagram of the environmental control liquid cooling system used for case analysis;

[0024] Figure 4 This is a split diagram of a single pipe section in the pipe network system. DETAILED DESCRIPTION

[0025] In order to more clearly illustrate the technical solution of the embodiment of the present invention, the present invention is described in detail below in conjunction with the drawings or specific implementation cases of the specification. It should be noted that some (but not all) of the disclosed examples are shown in the drawings. In fact, many different examples can be described and these examples should not be understood as being limited to the examples set forth herein. On the contrary, these examples are described so that the positive effects of the present invention are more reflected, and any parts not detailed in the text are regarded as known techniques or conventional technical means in the art.

[0026] This embodiment provides an equivalent simulation test technology and method for an environmental control liquid cooling system, including a flow resistance simulation component for equipment resistance simulation, a regulating valve for pipeline resistance simulation, a pressure sensor and corresponding simulation data, a pipeline heater for internal heat load simulation, and a wide temperature and wide flow heating and cooling integrated unit for external heat load simulation. The specific steps are as follows: Figure 2 , described as follows:

[0027] Step 1: Based on the three-dimensional digital model and working parameters of the actual aircraft environmental control liquid cooling system (hereinafter referred to as the "actual system"), four elements of the actual system are extracted: the heat generation power of the liquid-cooled electronic equipment (element one), the temperature and flow parameters of the fuel and gas interconnected with the actual system (element two), the three-dimensional digital model of the actual system liquid cooling equipment (element three), and the three-dimensional digital model of the actual system liquid cooling pipe network (element four);

[0028] Step 2:

[0029] Step 2.1: Determine the heater power for internal heat load simulation based on factor one;

[0030] Step 2.2: Determine the heating, cooling power and load capacity of the heating and cooling integrated unit for external heat load simulation based on factor 2;

[0031] Step 2.3: Determine the coolant flow channel dimension information and external dimensions of the liquid cooling device according to factor three, and calculate the coolant flow channel flow resistance data of the liquid cooling device through simulation software;

[0032] Step 2.4: Determine the connection relationship of the environmental control system pipe network according to factor 4, further disassemble to obtain a single pipe segment, obtain the pipe segment size information (diameter, length, bending angle, etc.) and pipe accessories such as three-way / four-way joints and reducers, and calculate the pipe segment flow resistance data in combination with simulation software; the method for splitting the pipe network system into multiple single pipelines is as follows: According to the actual pipe network digital model of aviation products (such as aircraft, etc.), the pipelines between adjacent equipment, between equipment and pipeline parts, and between adjacent pipeline parts are split into single pipelines: Figure 3 For the schematic diagram of an aviation product system, the pipelines between adjacent equipment, between equipment and pipeline parts (tees), and between adjacent pipeline parts (tees) are split to obtain Figure 4L1 to L14 are shown, a total of 14 sections of single pipeline.

[0033] Step 3:

[0034] Step 3.1: Select and design the pipeline heater according to the information in step 2.1, and manufacture / purchase the pipeline heater that meets the requirements;

[0035] Step 3.2: Select and design the heating and cooling integrated unit based on the information in step 2.2, and manufacture / purchase the heating and cooling integrated unit that meets the requirements;

[0036] Step 3.3: According to the flow channel size information and external dimensions in step 2.3, a flow resistance simulation structural part consistent with the coolant flow channel of the liquid cooling device is produced, or a regulating valve at a certain opening is obtained through simulation data and flow resistance calibration test, and the regulating valve at the certain opening is used as the flow resistance simulation part of the liquid cooling device;

[0037] Step 4: According to the external dimension information of the liquid cooling equipment in step 2.3, the pipe network connection relationship in step 2.4, the dimension information (diameter) of some pipe sections and the accessory information such as three-way / four-way joints and reducers, and the dimension information of the pipeline heater, heating and cooling integrated unit and the flow resistance simulation parts of the liquid cooling equipment determined in steps 3.1, 3.2 and 3.3, a three-dimensional digital model of the test bench of the environmental control liquid cooling system (hereinafter referred to as "test bench digital model") is constructed, in which the pipe sections are horizontal and vertical pipe sections to avoid special-shaped pipe sections;

[0038] Step 5: Use simulation software to calculate the pipe network and single pipe section flow resistance data of the test bench digital model, and compare and analyze with the actual system pipe section flow resistance data in step 2.4 to determine the test bench pipe section flow resistance simulation scheme. Among them, the simulated flow resistance value of the actual system pipe section is more than 10% larger than the simulated flow resistance value of the test bench digital model pipe section. It is necessary to add a regulating valve at the position of the corresponding pipe section of the test bench digital model for resistance simulation of this section of the pipe section. The simulated flow resistance value of the actual system pipe section is more than 10% smaller than the simulated flow resistance value of the test bench digital model pipe section. It is necessary to increase the pipe diameter or shorten the pipe length of the corresponding pipe section of the test bench digital model;

[0039] Step 6: Produce the test bench pipe section according to the test bench digital model pipe section adjusted in step 5, and connect it with the liquid cooling equipment simulation part, the pipeline heater, and the heating and cooling integrated unit to obtain an equivalent simulation test bench for the environmental control liquid cooling system.

[0040] An equivalent simulation test system for an environmental control liquid cooling system, the test system comprising: a thermal simulation unit, a flow resistance simulation unit;

[0041] The thermal simulation unit also includes an internal heat load simulation module and an external heat load simulation module. The internal heat load simulation module uses a pipeline heater connected in series to the system pipe network to simulate the heat generated by the environmental control liquid-cooled electronic equipment; the external load simulation module uses a heating and cooling integrated unit, which is interconnected with the system pipe network through a heat exchanger to simulate the heat exchange state between the external system and the environmental control system;

[0042] The flow resistance simulation unit also includes a liquid cooling device flow resistance simulation module and a liquid cooling pipeline flow resistance simulation module.

[0043] Among them, the liquid cooling equipment flow resistance simulation module produces and manufactures structural parts that are consistent with the actual liquid cooling equipment radiator flow channel based on the three-dimensional digital model of the actual liquid cooling equipment. Under the premise of ensuring the accuracy of the flow resistance of the simulated parts, the structure and manufacturing difficulty of the liquid cooling equipment test pieces are simplified; the liquid cooling pipeline flow resistance simulation module simulates the actual liquid cooling pipeline network resistance through regular straight pipelines and regulating valves and other flow resistance simulation mechanisms, thereby reducing the complexity of the test system pipeline network, improving the adaptability of the test system, and facilitating modular construction.

[0044] In the simulation system designed as above, the external system includes a fuel system, an external atmosphere system, external solar radiation, etc.

[0045] The above specific implementation methods or cases are only used to explain the technical solutions of the present invention, and are not intended to limit the present application. Any parts not described in detail are deemed to be conventional technical means or common knowledge in the field. It can be understood by ordinary technicians in this field that: based on the design concept of the present application, the technical solutions recorded in the aforementioned implementation methods should be adaptively modified, or some or all of the technical features therein should be replaced by equivalents. These modifications, equivalent replacements, and adaptively improved technical solutions do not depart from the technical essence of the present invention and should all be covered within the protection scope of the present application.

Claims

1. An equivalent simulation test method for an environmental control liquid cooling system, characterized in that: The actual environmental control system is simulated through flow resistance simulation and thermal simulation, and an environmental control system test bench is constructed to meet the test verification requirements of the environmental control system; the flow resistance simulation includes two parts: liquid cooling equipment resistance simulation and liquid cooling pipeline resistance simulation, and the equipment thermal simulation includes two parts: internal heat load and external heat load of the environmental control system.

2. An equivalent simulation test method for an environmental control liquid cooling system according to claim 1, characterized in that: The resistance simulation of liquid cooling equipment is carried out in the form of finished product flow resistance simulation parts, where the flow resistance simulation parts mainly refer to pure mechanical structural parts that are consistent with the appearance and internal flow channels of the actual finished product equipment and may not contain electronic components.

3. An equivalent simulation test method for an environmental control liquid cooling system according to claim 1, characterized in that: Liquid cooling pipeline resistance simulation simulates the real pipeline resistance by combining regulating valves, pipe accessories, straight pipe sections and simulation calculation data. The simulation calculation data refers to the flow resistance data of pipe sections and pipe network systems calculated by simulation software to build the relationship between flow rate and pressure drop.

4. An equivalent simulation test method for an environmental control liquid cooling system as claimed in claim 3, characterized in that: The regulating valve can achieve 0-90° stepless adjustment. The pipe accessories mainly include elbows, tees, crosses, reducers and other connectors. The straight pipe section refers to the entire section of pipe with unchanged diameter and no other connectors in the middle.

5. The equivalent simulation test method for an environmental control liquid cooling system according to claim 1, characterized in that: The resistance simulation of liquid cooling pipeline is divided into single pipe segment resistance simulation and multiple pipe segment resistance simulation. The single pipe segment resistance simulation means that a test bench straight pipe segment with a resistance simulation regulating valve is used to simulate the real straight pipe segment at the corresponding position. The multiple pipe segment resistance simulation means that a test bench straight pipe segment with a resistance simulation regulating valve is used to simulate multiple interconnected real straight pipe segments.

6. An equivalent simulation test method for an environmental control liquid cooling system according to claim 1, characterized in that: The internal heat load of the environmental control system refers to the total heat generated by electronic equipment that is directly connected to the environmental control liquid cooling system pipeline and directly dissipates heat through the environmental control liquid cooling system. The internal heat load is usually simulated by using a series pipe heater to allow the heater to directly heat the environmental control liquid cooling medium.

7. An equivalent simulation test method for an environmental control liquid cooling system according to claim 1, characterized in that: The external heat load of the environmental control system refers to the total heat of the heat medium that is indirectly interconnected with the environmental control liquid condenser system and exchanges heat with the environmental control liquid cooling system through an independent multi-channel heat exchanger. The liquid cooling equipment resistance simulation component includes the above-mentioned independent multi-channel heat exchanger. The external heat load is usually simulated by a wide-temperature and wide-flow cooling and heating integrated unit.

8. An equivalent simulation test system for an environmental control liquid cooling system, used to implement the equivalent simulation test method for an environmental control liquid cooling system as claimed in any one of claims 1 to 7, characterized in that: The test system comprises: a thermal simulation unit and a flow resistance simulation unit; The thermal simulation unit also includes an internal heat load simulation module and an external heat load simulation module. The internal heat load simulation module uses a pipeline heater connected in series to the system pipe network to simulate the heat generated by the environmental control liquid-cooled electronic equipment; the external load simulation module uses a heating and cooling integrated unit, which is interconnected with the system pipe network through a heat exchanger to simulate the heat exchange state between the external system and the environmental control system; The flow resistance simulation unit also includes a liquid cooling device flow resistance simulation module and a liquid cooling pipeline flow resistance simulation module. Among them, the liquid cooling equipment flow resistance simulation module produces and manufactures structural parts that are consistent with the actual liquid cooling equipment radiator flow channel based on the three-dimensional digital model of the actual liquid cooling equipment. While ensuring the accuracy of the flow resistance of the simulated parts, the structure and manufacturing difficulty of the liquid cooling equipment test pieces are simplified; the liquid cooling pipeline flow resistance simulation module simulates the actual liquid cooling pipeline network resistance through regular straight pipes and regulating valves and other flow resistance simulation mechanisms, thereby reducing the complexity of the test system pipeline network, improving the adaptability of the test system, and facilitating modular assembly.

9. An equivalent simulation test system for an environmental control liquid cooling system as claimed in claim 8, characterized in that: The external system includes a fuel system, an external atmosphere system, and external solar radiation.

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