Installation and debugging method of a biaxial compressor tester with same-side input

Abstract

The present application provides a method for installing and debugging a dual-axis compressor tester with same-side input, which belongs to the field of aero-engine testing. The method includes: installing an intake rail and an equipment steel platform; installing an intake pipe and an exhaust pipe; installing an exhaust system; installing and adjusting a test piece; installing a transmission system and a power system; installing and debugging an auxiliary system for supporting the operation of the main equipment; performing no-load operation debugging of the power system and the transmission system; driving the test piece through the power system through the transmission system to achieve the designed operating conditions of the test piece, completing the loaded joint debugging, and assessing whether the dual-axis compressor tester can meet the design indicators. The present application can achieve concentricity adjustment, test piece installation, joint debugging risk control, etc., which can improve test efficiency and success rate and shorten the debugging test cycle.

Description

Technical Field

[0001] The present application relates to the field of aero-engine testing, and in particular to a method for installing and debugging a dual-axis compressor tester with same-side input. Background Art

[0002] like Figure 1 As shown, the dual-axis compressor tester with same-side input mainly includes: the power system 10, transmission system 20, exhaust system 30, exhaust pipeline 40, test piece 50, intake pipeline 60 and other main equipment, as well as auxiliary systems such as lubricating oil system, hydraulic system, air system, water system, electrical system, control system, and test system. The test piece 50 is generally composed of a fan or low-pressure compressor as the outer shaft rotor, and a high-pressure compressor as the inner shaft rotor. The power system 10 includes an outer shaft power motor 11 and an inner shaft power motor 12. The transmission system 20 includes an outer shaft speed increaser 21, an inner shaft speed increaser 22, and a coaxial gearbox 23. The outer shaft speed increaser 21 and the inner shaft speed increaser 22 are respectively connected to the outer shaft power motor 11 and the inner shaft power motor 12, and drive the inner and outer shafts of the test piece 50 through the coaxial gearbox 23. The exhaust system 30 and exhaust pipeline 40 are used for exhaust, and the intake pipeline 60 is used to provide test gas with a suitable temperature and flow rate to the test piece 50. The dual-axis compressor tester has the characteristics of high speed, high exhaust temperature and pressure, and complex transmission structure, making it extremely difficult to install and debug.

[0003] There are no relevant specifications for the installation and commissioning of a biaxial compressor tester with same-side input in the prior art. Usually, the installation and commissioning of the equipment are carried out with reference to a conventional uniaxial compressor tester. However, the installation and commissioning with reference to a uniaxial compressor tester has the following disadvantages:

[0004] 1) The equipment installation sequence and debugging process are not adapted to the characteristics of the dual-axis compressor tester with same-side input, making it difficult to achieve fast and efficient installation and debugging;

[0005] 2) The concentricity adjustment method of the concentric transmission device with an outer sleeve and inner shaft, which is unique to the same-side input structure, is unclear, making it impossible to align the shaft system safely and quickly;

[0006] 3) There is a lack of scientific and effective methods for the installation and adjustment of the long cantilever support structure of the test piece with input on the same side;

[0007] 4) There is a lack of effective identification and control methods for risks such as high exhaust temperature and large shaft vibration during the debugging of the dual-axis compressor tester. Summary of the Invention

[0008] The purpose of the present application is to provide a method for installing and debugging a dual-axis compressor tester with same-side input, so as to solve or alleviate at least one problem in the background technology.

[0009] The technical solution of this application is: a method for installing and debugging a biaxial compressor tester with same-side input, comprising:

[0010] S10, installing an air intake rail and an equipment steel platform. The air intake rail is used to support an air intake pipeline. The air intake pipeline is installed on the air intake rail so that the air intake pipeline can move axially along the air intake rail. The equipment steel platform is used to install and fix the main equipment of the biaxial compressor tester, which includes the exhaust system, transmission system, power system, and test piece.

[0011] S20, installing an air intake pipe and an exhaust pipe. The air intake pipe is used to provide a uniform and stable air intake environment for the test piece and measure the air intake flow rate and air intake temperature. The exhaust pipe is used to discharge the high-temperature and high-pressure air exhausted from the test piece to an exhaust tower and measure the flow rate.

[0012] S30, installing an exhaust system, wherein the exhaust system serves as a positioning reference for the entire shaft system of the biaxial compressor tester;

[0013] S40, installing and adjusting the test piece, wherein the test piece is installed and positioned on the exhaust duct of the exhaust system via an exhaust casing cantilever, and an intermediate auxiliary support and a front auxiliary support are installed on the intermediate casing and the front casing of the test piece, respectively;

[0014] S50: Install the transmission system and power system, and simultaneously adjust the concentricity of each device in the transmission system and power system;

[0015] S60: Install and debug auxiliary systems used to support the operation of the main equipment, and verify the functional completeness of the auxiliary systems item by item;

[0016] S70: After completing the installation and commissioning of the main equipment and auxiliary systems, conduct no-load operation commissioning of the power system and transmission system to verify operational stability and control reliability;

[0017] S80, drives the test piece through the power system through the transmission system to achieve the designed operating conditions of the test piece and complete the load joint debugging, assessing whether the dual-axis compressor tester can meet the design indicators and verifying the load operation stability and functional completeness. Among them, the test piece is the entire compression system consisting of the fan and compressor.

[0018] Preferably, the process of installing the air intake rail and the equipment steel platform includes:

[0019] S11: Lay the air intake rails to ensure that the equipment in the air intake pipeline can move axially along the rails. When laying, ensure that the rails are level and parallel to the baseline of the plant.

[0020] S12, then adjusting the position of the equipment steel platform based on the air intake guide rail, determining the height and horizontal direction of the equipment steel platform based on the centerline and upper surface of the air intake guide rail, and determining the axial direction of the equipment steel platform based on the centerline of the exhaust duct of the exhaust system;

[0021] S13: The equipment steel platform is fixed to the cement foundation of the factory building in a block-by-block manner. The process includes:

[0022] First, accurately place the position of each equipment steel platform according to the reference line. Before placement, place the anchor bolts into the bolt holes to ensure that the gaps are even and parallel to each other.

[0023] Then, use the top screws and pads on each equipment steel platform to uniformly adjust the height of all equipment steel platforms to ensure the overall flatness of the equipment steel platforms;

[0024] Then pour non-shrinkage cement into the bolt hole of each anchor bolt, wait for the cement to solidify and reach the strength standard, and then tighten the anchor bolts of the equipment steel platform;

[0025] Finally, fill the gap between the cement foundation and the equipment steel platform with non-shrinkage cement;

[0026] S14: After the equipment steel platform is installed and meets the strength requirements after maintenance, the main equipment can be installed.

[0027] Preferably, the intake pipe includes a flow tube, an intake throttle, an expansion section, and a pressure stabilizing box. When installed, the intake pipe is parallel to the intake guide rail and can move axially on the intake guide rail to facilitate the disassembly and assembly of the test piece. When installing the exhaust pipe, ensure that the axis of the exhaust pipe is not skewed. The exhaust pipe is supported by a support frame, and the exhaust pipe can move freely on the support frame to avoid high-temperature thermal expansion affecting the positioning of the main equipment.

[0028] Preferably, the exhaust system includes an exhaust duct, an exhaust volute and a support base. The exhaust duct is fixed to the equipment steel platform through four support bases. The test piece and the exhaust volute are respectively connected to the inlet and outlet sides of the exhaust duct.

[0029] During the installation process, a laser level is used to adjust the pads to ensure the height consistency of the four support seats, and to ensure that the contact degree of each support surface after connection with the exhaust duct is not less than 80%. Finally, a frame level is used to check the verticality of the connection surface between the exhaust duct and the test piece after installation to ensure that the axis of the exhaust system is parallel to the axis of the equipment steel platform.

[0030] Preferably, the process of installing and positioning the test piece on the exhaust duct of the exhaust system by means of an exhaust casing cantilever is as follows: the test piece is horizontally lifted by a lifting device, the test piece is moved to ensure that the exhaust casing mounting edge of the test piece is aligned with the exhaust duct mounting edge, and the main support is connected and fastened by bolts. After the main support is fastened, the horizontality of the test piece is checked by a spirit level, and the test piece is kept level by adjusting the lifting device. During this process, the test piece is kept lifted to prevent the inlet of the test piece from sinking.

[0031] The process of installing the intermediate auxiliary support and the front auxiliary support at the intermediate receiver and the front receiver of the test piece respectively is as follows: keep the test piece in a hoisted state to install the intermediate auxiliary support, and gradually adjust the height of the support seat until it fits with the intermediate receiver of the test piece. During the height adjustment of the intermediate auxiliary support, the height change of the test piece is monitored by a dial indicator to ensure that the vertical change of the intermediate receiver of the test piece is no more than 0.05mm. At the same time, the horizontality of the test piece is checked by a spirit level to avoid the axis deviation of the test piece; the front auxiliary support is installed according to the same principle.

[0032] Preferably, the transmission system includes a coaxial gearbox and an outer shaft speed increaser, an inner shaft speed increaser, a transmission shaft, and a coupling; the power system includes an outer shaft power motor, an inner shaft power motor, and a matching turning device and encoder;

[0033] First, the transmission system and power system equipment are preliminarily positioned according to their theoretical dimensions, and the horizontal, vertical, and axial positions of each device are roughly adjusted to ensure that the deviation in each direction is within the coupling compensation range. Then, the transmission system coupling and drive shaft are driven by the turning device to drive the outer and inner shafts of the test piece respectively, and the concentricity of each device is checked and adjusted one by one using a laser alignment instrument.

[0034] Among them, the order of adjusting the concentricity of each device of the transmission system and the power system is: coaxial gearbox, external shaft speed increaser, external shaft power motor, internal shaft speed increaser, and internal shaft power motor, specifically including: the coaxial gearbox concentricity adjustment benchmark is the test piece installed on the exhaust duct, and the concentricity of the coaxial gearbox is adjusted only with the external shaft alignment as the judgment standard; after completing the coaxial gearbox concentricity adjustment, adjust the concentricity of the external shaft speed increaser and the internal shaft speed increaser respectively with the coaxial gearbox as the benchmark; then adjust the concentricity of the external shaft power motor with the external shaft speed increaser as the benchmark, and adjust the concentricity of the inner shaft power motor with the inner shaft speed increaser as the benchmark.

[0035] Preferably, the auxiliary systems include an oil system, a hydraulic system, an air system, and a water system. The installation and commissioning process of each auxiliary system includes:

[0036] S61: Ensure that the oil supply and return pumps of the lubricating oil system operate normally and that the oil supply flow, pressure, and temperature meet the lubrication requirements of each equipment;

[0037] S62, ensures the stability of the hydraulic system's oil pressure to meet the test piece's adjustable blade angle, exhaust throttle, and hydraulic valve adjustment requirements;

[0038] S63, ensure the air system's air supply is stable, with adjustable pressure and flow to meet the sealing requirements of test pieces and various equipment;

[0039] S64, ensure that the water supply flow and pressure of the water system meet the cooling needs of various equipment.

[0040] Preferably, the process of performing no-load operation commissioning of the power system and the transmission system includes:

[0041] S71: Conduct no-load operation debugging of the external shaft power motor and the internal shaft power motor separately to verify the completeness of the speed control function and the stability of the motor operation;

[0042] S72: Jointly conduct no-load operation commissioning of the outer shaft power motor and the inner shaft power motor to verify the speed distribution and linkage control functions;

[0043] S73, respectively carry out no-load operation debugging of the outer shaft power motor, the inner shaft power motor and the adapted speed increaser to verify the speed increaser operation stability;

[0044] S74, carry out no-load operation commissioning of the inner shaft power motor, outer shaft power motor, adapted speed increaser and coaxial gearbox;

[0045] S75: During the commissioning process, the shaft system vibration and bearing temperature are detected to ensure that the equipment is operating normally and meets the conditions for subsequent load-carrying joint commissioning.

[0046] Preferably, the process of performing on-load joint debugging includes:

[0047] S81: Run-in the fan and compressor along the blockage points and increase the speed to the design speed, conduct no-load operation debugging of each system, and assess the operational stability of the equipment under load;

[0048] S82, recording the performance of the fan and compressor from the blockage point to the maximum efficiency point, evaluating the test data by combining the test results of the biaxial compressor tester and the simulation calculation results, and analyzing the test accuracy of key parameters, including pressure, temperature, flow rate, speed, and torque;

[0049] S83, records the performance of the compressor from the blocking point to the breathing point, verifying the completeness and reliability of the forced breathing, retreated breathing, and state recovery functions;

[0050] S84, adjust the fan bypass ratio and the internal and external shaft speed difference respectively, record the fan and compressor performance under different matching conditions, and verify the completeness of the matching characteristics research function.

[0051] The installation and debugging method of a dual-axis compressor tester with same-side input proposed in this application can realize concentricity adjustment, test piece installation, joint debugging risk control, etc., which can improve test efficiency and success rate and shorten the debugging test cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] In order to more clearly illustrate the technical solutions provided by this application, the following is a brief introduction to the accompanying drawings. Obviously, the accompanying drawings described below are only some embodiments of this application.

[0053] Figure 1 Schematic diagram of a biaxial compressor tester with same-side input in the prior art.

[0054] Figure 2 Schematic diagram of the installation and debugging method of the dual-axis compressor tester with same-side input in this application.

[0055] Reference numerals:

[0056] 10-Powertrain

[0057] 11-External shaft power motor

[0058] 12-Inner shaft power motor

[0059] 20-Transmission system

[0060] 21-External shaft speed increaser

[0061] 22-Inner shaft speed increaser

[0062] 23-Coaxial gearbox

[0063] 30-Exhaust system

[0064] 40-Exhaust pipe

[0065] 50-test piece

[0066] 60-Intake pipe

[0067] 70-Equipment Steel Platform DETAILED DESCRIPTION

[0068] In order to make the purpose, technical solutions and advantages of the implementation of this application clearer, the technical solutions in the embodiments of this application will be described in more detail below in conjunction with the drawings in the embodiments of this application.

[0069] like Figure 2 As shown, the installation and debugging method of the biaxial compressor tester with same-side input proposed in this application includes the following process:

[0070] S10, installation of air intake rails and equipment steel platforms, used to provide an installation foundation for each main equipment.

[0071] In this application, the air intake rail is used to support the air intake pipe 60. In order to adapt to the length of different test pieces 50 and facilitate the disassembly and assembly of the test pieces 50, the air intake pipe 60 is installed on the air intake rail and supported by the air intake rail to facilitate its axial movement.

[0072] The equipment steel platform 70 is used to mount and secure the biaxial compressor tester's main components, including the exhaust system 30, transmission system 20, power system 10, and test piece 50. It serves as the supporting foundation for the entire biaxial compressor tester. The high flatness of the equipment steel platform 70 facilitates adjustment of the main components after installation and ensures proper shaft alignment.

[0073] The process of installing the air intake rail and equipment steel platform 70 includes:

[0074] S11. First, the air intake rail is laid to ensure that the air intake pressure regulating box and other air intake equipment can move axially along the air intake rail. When laying, the air intake rail is kept horizontal and parallel to the baseline of the factory building.

[0075] S12, then adjust the position of the equipment steel platform 70 based on the intake guide rail, locate the height and horizontal direction of the equipment steel platform 70 based on the center line and upper surface of the intake guide rail, and locate the axial direction of the equipment steel platform 70 based on the center line of the exhaust duct of the exhaust system 30.

[0076] S13. Considering the large dimensions of the dual-axial compressor tester with input from the same side, both in the axial direction (approximately 17 meters) and the horizontal direction (approximately 9 meters), the equipment steel platform 70 is typically arranged in sections, each of which is fixed to the concrete foundation of the factory building. First, accurately position each equipment steel platform with reference to the baseline (place the anchor bolts in the bolt holes before placement), ensuring uniform gaps and parallelism. Then, using the top screws and spacers on each equipment steel platform, uniformly adjust the height of all equipment steel platforms to ensure the overall flatness of equipment steel platform 70. Then, pour non-shrinkage cement into each anchor bolt hole. After the cement solidifies and reaches the required strength, tighten the anchor bolts at each location of equipment steel platform 70. Finally, fill the gap between the concrete foundation and the equipment steel platform with non-shrinkage cement.

[0077] S14: After the equipment steel platform 70 is installed and meets the strength requirements after maintenance, the exhaust system 30, transmission system 20 and power system 10 and other equipment can be installed.

[0078] S20 , the installation of the intake pipe 60 and the exhaust pipe 40 provides a positioning reference for the installation of the exhaust system 30 .

[0079] The intake line 60 typically includes a flow tube, an intake throttle, an expansion section, a pressure regulator, and other equipment. It provides a uniform and stable intake environment for the test piece 50 and measures parameters such as intake flow rate and temperature. The intake line 60 is installed parallel to the intake rail and is free to move axially on the rail, facilitating assembly and disassembly of the test piece 50.

[0080] Exhaust pipe 40 is used to discharge high-temperature, high-pressure air from test piece 30 to an exhaust tower for flow measurement. During installation, ensure that the exhaust pipe 40's axis is not deflected. Exhaust pipe 40 is supported by a support frame, allowing it to move freely on the support frame to prevent thermal expansion from affecting the main equipment's positioning.

[0081] S30 , installing the exhaust system 30 to provide support for the test piece 50 .

[0082] For a biaxial compressor tester with same-side input, the exhaust system serves as the positioning reference for the entire shaft system and therefore needs to be installed first. The exhaust system 30 primarily comprises the exhaust duct, exhaust volute, and support brackets. The exhaust duct is secured to the equipment's steel platform 70 via four support brackets. The test specimen 50 and exhaust volute are connected to the exhaust duct's inlet and outlet, respectively.

[0083] During the installation of the exhaust system 30, a laser level was used to ensure the height consistency of the four support brackets using adjustment pads. The contact between each support surface and the exhaust duct was to be at least 80%. Finally, a frame level was used to check the verticality of the connection surface between the exhaust duct and the test piece 50 after installation, ensuring that the axis of the exhaust system 30 was parallel to the axis of the equipment steel platform 70.

[0084] S40, installation and adjustment of the test piece 50, provides a reference for subsequent adjustment of the concentricity of the equipment.

[0085] Test piece 50 is the test subject of a dual-axis compressor tester with ipsilateral input. It is mounted on the exhaust duct of exhaust system 30 via an exhaust case cantilever for positioning. Test piece 50 is characterized by its long axial length and heavy weight. Relying solely on the exhaust duct for fixation inevitably results in inlet sinking. To ensure reliable positioning of the long cantilever structure under high-speed rotation, in addition to the exhaust case serving as the primary support, intermediate and front auxiliary supports are installed on the intermediate and front cases of test piece 50, respectively.

[0086] Considering that both ends of the inner shaft transmission shaft between the test piece 50 and the coaxial gearbox 23 are usually spline-driven and have limited radial compensation capabilities, only the outer shaft coupling is installed when the test piece 50 is adjusted for the first time. The test piece 50 can only be removed when the centering deviation between the coaxial gearbox 23 and the test piece 50 is within the compensation range of the inner shaft spline. After the inner shaft transmission shaft is installed, the test piece 50 can be installed again.

[0087] During installation, the test specimen 50 is first hoisted horizontally using a lifting fixture. The specimen 50 is then smoothly moved to ensure that the exhaust casing mounting edge of the specimen 50 aligns with the exhaust duct mounting edge. The main supports are then connected and secured using bolts. The specimen 50 is kept suspended during this process to prevent the inlet of the specimen 50 from sinking. After the main supports are secured, the specimen 50 is checked for levelness using a spirit level and the lifting fixture is adjusted to ensure it remains level.

[0088] While keeping the test specimen 50 suspended, install the intermediate auxiliary support and gradually adjust the support base height until it aligns with the intermediate housing of the test specimen 50. During this adjustment, monitor the height of the test specimen 50 using a dial indicator to ensure that the vertical change in the intermediate housing of the test specimen 50 does not exceed 0.05 mm. Simultaneously, check the horizontality of the test specimen 50 using a spirit level to prevent axial deviation of the test specimen 50.

[0089] Install the front auxiliary support according to the same principle.

[0090] Through the above process, it can be ensured that the middle auxiliary support and the front auxiliary support can effectively support the vertical direction of the test piece 50, and it can avoid that the test piece 50 is over-constrained due to multiple supports. In addition, the test piece 50 can remain in a horizontal state after installation, which is convenient for the concentricity adjustment of the back-end equipment.

[0091] S50 , the transmission system 20 and the power system 10 are installed to provide driving power for the test piece 50 .

[0092] The transmission system 20 of the dual-axis compressor tester with same-side input includes a coaxial gearbox 23 and two first-stage speed increasers (i.e., the outer shaft speed increaser 21 and the inner shaft speed increaser 22), as well as transmission shafts, couplings and other equipment; the power system 10 includes two power motors (i.e., the outer shaft power motor 11 and the inner shaft power motor 12) and supporting turning devices, encoders and other equipment.

[0093] First, each device is initially positioned according to its theoretical dimensions, and its horizontal, vertical, and axial positions are roughly adjusted to ensure that deviations in each direction are within the coupling's compensation range. The coupling and drive shaft in transmission system 20 then drive the outer and inner shafts of test piece 50, respectively, using a turning mechanism. A laser alignment system is then used to check and adjust the concentricity of each device individually.

[0094] The order of adjusting the concentricity of each device is: coaxial gearbox 23, outer shaft speed increaser 21, outer shaft power motor 11, inner shaft speed increaser 22, inner shaft power motor 12.

[0095] The benchmark for adjusting the concentricity of the coaxial gearbox 23 is the test piece 50 mounted on the exhaust duct. Because both the coaxial gearbox 23 and the test piece 50 are concentric transmission structures with an outer shaft within an inner shaft, the coaxiality between the inner and outer shafts is guaranteed by the structure. Therefore, the concentricity of the equipment is judged solely on the alignment of the outer shaft.

[0096] After completing the concentricity adjustment of the coaxial gearbox 23, the concentricity of the outer shaft speed increaser 21 and the inner shaft speed increaser 22 are adjusted respectively based on the coaxial gearbox 23; then the concentricity of the outer shaft power motor 11 is adjusted based on the outer shaft speed increaser 21, and the concentricity of the inner shaft power motor 12 is adjusted based on the inner shaft speed increaser 22.

[0097] Because the twin-axis compressor tester with same-side input features a long axis (over 10 meters), even a slight deviation in the axis of the front-end equipment can result in significant offset in the rear-end equipment. If the rear-end equipment adjustment exceeds the compensation range, the front-end equipment alignment should be rechecked and appropriate pre-biasing should be considered if necessary.

[0098] S60, installation and commissioning of auxiliary systems, used to support the operation of the main equipment and verify the functional completeness item by item.

[0099] Auxiliary systems include lubricating oil system, hydraulic system, air system, water system, etc. After the main equipment is installed and positioned, the installation and connection of the auxiliary systems should be carried out to avoid restrictions on the position adjustment of the main equipment after the auxiliary systems are installed.

[0100] The installation and commissioning process of each auxiliary system includes:

[0101] S61: Ensure that the oil supply and return pumps of the lubricating oil system operate normally, and that the oil supply flow, pressure, and temperature meet the lubrication requirements of each equipment;

[0102] S62, the oil pressure of the hydraulic system should be kept stable to meet the adjustment requirements of the test piece 50, such as the adjustable blade angle, exhaust throttle, and hydraulic valve;

[0103] S63, the air supply of the air system should be stable, with adjustable pressure and flow, to meet the sealing requirements of the test piece 50 and various equipment;

[0104] S64: Ensure that the water supply flow and pressure of the water system meet the cooling requirements of each equipment;

[0105] S65, the debugging of other subsystems should ensure that the basic conditions for subsequent no-load operation debugging and load combined debugging are met. Other additional functions can be gradually completed during the subsequent debugging process.

[0106] S70, no-load operation debugging, verifying the equipment operation stability and control reliability;

[0107] After completing the installation of the main equipment and the installation and commissioning of the auxiliary systems, the no-load operation commissioning of the power system 10 and the transmission system 20 is carried out to verify their operating stability and control reliability.

[0108] The no-load operation debugging sequence of the dual-axis compressor tester with the same-side input is as follows:

[0109] S71, separately carry out no-load operation debugging of the outer shaft power motor 11 and the inner shaft power motor 12 to verify the completeness of the speed control function and the stability of the motor operation;

[0110] S72, jointly carry out no-load operation debugging of the outer shaft power motor 11 and the inner shaft power motor 12 to verify the speed transfer / interlocking control function;

[0111] S73, performing no-load operation debugging of the outer shaft power motor 11, the inner shaft power motor 12 and the corresponding speed increaser to verify the speed increaser operation stability;

[0112] S74, carrying out no-load operation debugging of the inner shaft power motor 12, the outer shaft power motor 11, the corresponding speed increaser and the coaxial gearbox 23;

[0113] S75: During the commissioning process, parameters such as shaft system vibration and bearing temperature are tested to ensure that the equipment is operating normally and meets the conditions for subsequent load-carrying joint commissioning.

[0114] S80, on-load combined debugging, assesses the design indicators of the dual-axis compressor tester and verifies the reliability and functional completeness of on-load operation.

[0115] Combined on-load commissioning involves driving the test article 50 through the power system 10 and the transmission system 20 to achieve its designed operating conditions. This test evaluates whether the dual-axial compressor tester can meet design specifications and verifies its reliability and functional integrity during on-load operation. The test article 50 for the dual-axial compressor tester with the same-side input is the entire compression system consisting of the fan and compressor.

[0116] The combined load debugging should gradually improve the test conditions according to the characteristics of the test piece. The main debugging steps include:

[0117] S81: Run-in the fan and compressor along the blockage points and increase the speed to the design speed, conduct no-load operation debugging of each system, and assess the operational stability of the equipment under load;

[0118] S82 records the performance of the fan and compressor from the blockage point to the highest efficiency point. The test data are evaluated by combining the test results of the biaxial compressor tester and the simulation calculation results to analyze the test accuracy of key parameters such as pressure, temperature, flow, speed, and torque;

[0119] S83, records the performance of the compressor from the blocking point to the breathing point, verifying the completeness and reliability of the functions such as forced breathing, breathing relief, and state recovery;

[0120] S84, adjust the fan bypass ratio, internal and external shaft slip and other variables respectively, record the fan and compressor performance under different matching conditions, and verify the completeness of the matching characteristics research function.

[0121] The main risks faced in debugging a dual-axis compressor tester include: the high pressure ratio characteristics of the multi-stage compression system lead to high exhaust temperatures, which in turn affect the stable operation of surrounding equipment; the long span, multiple support points, and concentric transmission structure lead to complex shaft system vibration characteristics, and excessive vibration affects high-speed operation. To address debugging risks, this application adopts the following control methods:

[0122] 1) Provide heat insulation wrapping on the outside of high-temperature components (such as exhaust volute, exhaust casing, etc.) to prevent high-temperature heat radiation from affecting surrounding equipment;

[0123] 2) Use cooling air to cool and insulate heat-sensitive components (such as hydraulic actuators, vibration sensors, etc.) to prevent high-temperature failure of precision components;

[0124] 3) Arrange temperature monitoring in high-temperature environments and on equipment surfaces in a reasonable manner. When the temperature approaches the limit value, take measures such as reducing the test state in a timely manner to avoid serious consequences of equipment failure;

[0125] 4) In high temperature environments, thermal expansion and deformation of supports affect equipment positioning. Reasonable concentricity can be reserved to optimize the alignment of the shaft system during operation to avoid excessive vibration.

[0126] 5) The characteristics of the long shaft system are complex rotor dynamic characteristics and a large number of critical speeds. The machine balancing method can be used to optimize the balance during operation and reduce vibration response;

[0127] 6) Synchronous rotation of the inner and outer shafts at high speeds is prone to vibration coupling. This can be avoided by adjusting the internal and external shaft speed difference as appropriate.

[0128] The installation and debugging method of a dual-axis compressor tester with same-side input proposed in this application can realize concentricity adjustment, test piece installation, joint debugging risk control, etc., which can improve test efficiency and success rate and shorten the debugging test cycle.

[0129] The above description is merely a specific embodiment of the present application, but the scope of protection of the present application is not limited thereto. Any changes or substitutions that can be easily conceived by a person skilled in the art within the technical scope disclosed in this application should be included in the scope of protection of the present application. Therefore, the scope of protection of the present application should be based on the scope of protection of the claims.

Claims

1. A method for installing and debugging a biaxial compressor tester with same-side input, characterized in that: include: S10, installing an air intake rail and an equipment steel platform. The air intake rail is used to support an air intake pipeline. The air intake pipeline is installed on the air intake rail so that the air intake pipeline can move axially along the air intake rail. The equipment steel platform is used to install and fix the main equipment of the biaxial compressor tester, which includes the exhaust system, transmission system, power system, and test piece. S20, installing an air intake pipe and an exhaust pipe. The air intake pipe is used to provide a uniform and stable air intake environment for the test piece and measure the air intake flow rate and air intake temperature. The exhaust pipe is used to discharge the high-temperature and high-pressure air exhausted from the test piece to an exhaust tower and measure the flow rate. S30, installing an exhaust system, wherein the exhaust system serves as a positioning reference for the entire shaft system of the biaxial compressor tester; S40, installing and adjusting the test piece, wherein the test piece is installed and positioned on the exhaust duct of the exhaust system via an exhaust casing cantilever, and an intermediate auxiliary support and a front auxiliary support are installed on the intermediate casing and the front casing of the test piece, respectively; S50: Install the transmission system and power system, and simultaneously adjust the concentricity of each device in the transmission system and power system; S60: Install and debug auxiliary systems used to support the operation of the main equipment, and verify the functional completeness of the auxiliary systems item by item; S70: After completing the installation and commissioning of the main equipment and auxiliary systems, conduct no-load operation commissioning of the power system and transmission system to verify operational stability and control reliability; S80, drives the test piece through the power system through the transmission system to achieve the designed operating conditions of the test piece and complete the load joint debugging, assessing whether the dual-axis compressor tester can meet the design indicators and verifying the load operation stability and functional completeness. Among them, the test piece is the entire compression system consisting of the fan and compressor.

2. The installation and debugging method of the same-side input biaxial compressor tester according to claim 1, characterized in that: The process of installing the air intake rail and equipment steel platform includes: S11: Lay the air intake rails to ensure that the equipment in the air intake pipeline can move axially along the rails. When laying, ensure that the rails are level and parallel to the baseline of the plant. S12, then adjusting the position of the equipment steel platform based on the air intake guide rail, determining the height and horizontal direction of the equipment steel platform based on the centerline and upper surface of the air intake guide rail, and determining the axial direction of the equipment steel platform based on the centerline of the exhaust duct of the exhaust system; S13: The equipment steel platform is fixed to the cement foundation of the factory building in a block-by-block manner. The process includes: First, refer to the reference line to place the position of each equipment steel platform. Before placement, place the anchor bolts into the bolt holes to ensure that the gaps are even and parallel to each other. Then, use the top screws and pads on each equipment steel platform to uniformly adjust the height of all equipment steel platforms to ensure the overall flatness of the equipment steel platforms; Then pour non-shrinkage cement into the bolt hole of each anchor bolt, wait for the cement to solidify and reach the strength standard, and then tighten the anchor bolts of the equipment steel platform; Finally, fill the gap between the cement foundation and the equipment steel platform with non-shrinkage cement; S14: After the equipment steel platform is installed and meets the strength requirements after maintenance, the main equipment can be installed.

3. The installation and debugging method of the same-side input biaxial compressor tester according to claim 2, characterized in that: The intake pipe includes a flow tube, an intake throttle, an expansion section, and a pressure stabilizing box. When installed, the intake pipe is parallel to the intake guide rail and can move axially on the intake guide rail to facilitate the disassembly and assembly of the test piece. When installing the exhaust pipe, ensure that the axis of the exhaust pipe is not skewed. The exhaust pipe is supported by a support frame, and the exhaust pipe can move freely on the support frame to avoid high-temperature thermal expansion affecting the positioning of the main equipment.

4. The installation and debugging method of a biaxial compressor tester with same-side input according to claim 3, characterized in that: The exhaust system includes an exhaust duct, an exhaust volute and a support base. The exhaust duct is fixed to the equipment steel platform through four support bases. The test piece and the exhaust volute are respectively connected to the inlet and outlet sides of the exhaust duct; During the installation process, a laser level is used to adjust the pads to ensure the height consistency of the four support seats, and to ensure that the contact degree of each support surface after connection with the exhaust duct is not less than 80%. Finally, a frame level is used to check the verticality of the connection surface between the exhaust duct and the test piece after installation to ensure that the axis of the exhaust system is parallel to the axis of the equipment steel platform.

5. The installation and debugging method of a biaxial compressor tester with same-side input according to claim 4, characterized in that: The process of installing and positioning the test piece on the exhaust duct of the exhaust system through the exhaust casing cantilever is as follows: the test piece is lifted horizontally by a hoist, the test piece is moved to ensure that the exhaust casing mounting edge of the test piece is aligned with the exhaust duct mounting edge, and the main support is connected and fastened by bolts. After the main support is fastened, the horizontality of the test piece is checked by a spirit level and the hoist is adjusted to ensure that the test piece is level. During this process, the test piece is kept lifted to prevent the inlet of the test piece from sinking. The process of installing the intermediate auxiliary support and the front auxiliary support at the intermediate receiver and the front receiver of the test piece respectively is as follows: keep the test piece in a hoisted state to install the intermediate auxiliary support, and gradually adjust the height of the support seat until it fits with the intermediate receiver of the test piece. During the height adjustment of the intermediate auxiliary support, the height change of the test piece is monitored by a dial indicator to ensure that the vertical change of the intermediate receiver of the test piece is no more than 0.05mm. At the same time, the horizontality of the test piece is checked by a spirit level to avoid the axis deviation of the test piece; the front auxiliary support is installed according to the same principle.

6. The installation and debugging method of a biaxial compressor tester with same-side input according to claim 5, characterized in that: The transmission system includes a coaxial gearbox and an outer shaft speed increaser, an inner shaft speed increaser, a transmission shaft, and a coupling. The power system includes an outer shaft power motor, an inner shaft power motor, and a matching turning device and encoder. First, the transmission system and power system equipment are preliminarily positioned according to their theoretical dimensions, and the horizontal, vertical, and axial positions of each device are roughly adjusted to ensure that the deviation in each direction is within the coupling compensation range. Then, the transmission system coupling and drive shaft are driven by the turning device to drive the outer and inner shafts of the test piece respectively, and the concentricity of each device is checked and adjusted one by one using a laser alignment instrument. Among them, the order of adjusting the concentricity of each device of the transmission system and the power system is: coaxial gearbox, external shaft speed increaser, external shaft power motor, internal shaft speed increaser, and internal shaft power motor, specifically including: the coaxial gearbox concentricity adjustment benchmark is the test piece installed on the exhaust duct, and the concentricity of the coaxial gearbox is adjusted only with the external shaft alignment as the judgment standard; after completing the coaxial gearbox concentricity adjustment, adjust the concentricity of the external shaft speed increaser and the internal shaft speed increaser respectively with the coaxial gearbox as the benchmark; then adjust the concentricity of the external shaft power motor with the external shaft speed increaser as the benchmark, and adjust the concentricity of the inner shaft power motor with the inner shaft speed increaser as the benchmark.

7. The installation and debugging method of a biaxial compressor tester with same-side input according to claim 6, characterized in that: The auxiliary systems include lubricating oil system, hydraulic system, air system, and water system. The installation and commissioning process of each auxiliary system includes: S61: Ensure that the oil supply and return pumps of the lubricating oil system operate normally and that the oil supply flow, pressure, and temperature meet the lubrication requirements of each equipment; S62, ensures the stability of the hydraulic system's oil pressure to meet the test piece's adjustable blade angle, exhaust throttle, and hydraulic valve adjustment requirements; S63, ensure the air system's air supply is stable, with adjustable pressure and flow to meet the sealing requirements of test pieces and various equipment; S64, ensure that the water supply flow and pressure of the water system meet the cooling needs of various equipment.

8. The installation and debugging method of a biaxial compressor tester with same-side input according to claim 7, characterized in that: The process of no-load commissioning of the power system and transmission system includes: S71: Conduct no-load operation debugging of the external shaft power motor and the internal shaft power motor separately to verify the completeness of the speed control function and the stability of the motor operation; S72: Jointly conduct no-load operation commissioning of the outer shaft power motor and the inner shaft power motor to verify the speed distribution and linkage control functions; S73, respectively carry out no-load operation debugging of the outer shaft power motor, the inner shaft power motor and the adapted speed increaser to verify the speed increaser operation stability; S74, carry out no-load operation commissioning of the inner shaft power motor, outer shaft power motor, adapted speed increaser and coaxial gearbox; S75: During the commissioning process, the shaft system vibration and bearing temperature are detected to ensure that the equipment is operating normally and meets the conditions for subsequent load-carrying joint commissioning.

9. The installation and debugging method of a biaxial compressor tester with same-side input according to claim 8, characterized in that: The process of joint load debugging includes: S81: Run-in the fan and compressor along the blockage points and increase the speed to the design speed, conduct no-load operation debugging of each system, and assess the operational stability of the equipment under load; S82, recording the performance of the fan and compressor from the blockage point to the maximum efficiency point, evaluating the test data by combining the test results of the biaxial compressor tester and the simulation calculation results, and analyzing the test accuracy of key parameters, including pressure, temperature, flow rate, speed, and torque; S83, records the performance of the compressor from the blocking point to the breathing point, verifying the completeness and reliability of the forced breathing, retreated breathing, and state recovery functions; S84, adjust the fan bypass ratio and the internal and external shaft speed difference respectively, record the fan and compressor performance under different matching conditions, and verify the completeness of the matching characteristics research function.

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