Aero-engine rotor maneuvering flight simulation device and method based on non-contact electromagnetic force loading

Abstract

The invention discloses an aero-engine rotor maneuvering flight simulation device and method based on non-contact electromagnetic force loading, and belongs to the technical field of aero-engine rotor vibration experiments. The device comprises a rotor tester system and an electromagnetic vibration exciter experiment system, the rotor tester system simulates rotation of an engine rotor system, and the electromagnetic vibration exciter experiment system comprises at least two electromagnetic vibration exciter actuators and an electromagnetic vibration exciter controller. Force / torque is directly applied to a rotor in a non-contact manner through a magnetic field generated by an electromagnetic vibration exciter actuator, and force / torque generated by an electromagnetic vibration exciter is controlled by an electromagnetic vibration exciter controller, so that direct, dynamic, high-precision and non-contact simulation of a complex load generated by maneuvering flight is realized; therefore, the problems that an existing simulation device based on mechanical motion is complex in structure and difficult to control, additional interference is introduced, loads cannot be accurately and dynamically controlled, and non-contact loading is difficult to achieve are solved.

Description

Technical Field

[0001] This invention belongs to the field of aero-engine rotor vibration testing technology, specifically relating to a test device and method for simulating the maneuvering flight of an aero-engine rotor system, and in particular, a test system for achieving high-precision dynamic simulation of maneuvering flight loads based on non-contact electromagnetic force direct loading technology. Background Technology

[0002] Maneuverability is a crucial performance indicator for aircraft. The demands for high thrust-to-weight ratio and high maneuverability have driven aero-engine design towards higher speeds, heavier loads, and more flexible structures, making vibration a critical technological bottleneck. During maneuvers such as dives, climbs, rolls, and yaws, the rotor system is subjected to complex dynamic loads, including additional centrifugal inertial forces and additional gyroscopic moments. These loads can lead to deformation of elastic supports, a surge in bearing loads, and intensified rotor vibration, significantly increasing the risk of vibration failure in the engine rotor system. Therefore, accurately simulating loads under maneuvering flight conditions and conducting rotor dynamics experiments are essential to ensure that the rotor system design meets operational requirements.

[0003] Existing technologies primarily employ mechanical motion platforms (such as turntables or multi-axis motor-driven lifting / rotating / tumbling platforms) to physically replicate the aircraft's maneuvering attitude, thereby indirectly applying maneuvering loads to the rotor system and simulating the force loads on the rotor system during maneuvering flight. However, existing mechanical motion-based simulation devices generally suffer from the following drawbacks: 1. Multi-axis motion platforms, linkages, slide rails and other mechanical structures are large and precise, which makes the design, manufacturing, installation and commissioning extremely complex, maintenance difficult and significantly increases costs.

[0004] 2. In flight simulation, it is necessary to accurately coordinate the position, velocity and acceleration of multiple degrees of freedom. Multivariable strongly coupled control algorithms are complex, have poor real-time performance, and are difficult to accurately simulate rapidly changing transient maneuver loads.

[0005] 3. Essentially, it generates inertial force indirectly by changing the attitude, making it impossible to directly, independently, and with high precision control over the force vector and torque applied to the rotor body or its supports. In particular, its ability to simulate high-frequency and transient loads is severely inadequate. Furthermore, the loading process involves physical motion and contact, inevitably introducing problems such as friction, wear, added mass, added stiffness, and added damping, which interfere with the true dynamic response of the rotor system.

[0006] Therefore, there is a need to provide a flight simulation device and method for aero-engine rotor maneuvering based on non-contact electromagnetic force loading to solve the above problems. Summary of the Invention

[0007] To overcome the shortcomings of existing technologies, this invention provides a rotor maneuvering flight simulation device and method for aero-engines based on non-contact electromagnetic force loading. The device simulates rotor rotation using a rotor test system, and an electromagnetic vibrator actuator is installed at the drum of the rotor system. The magnetic field generated by the electromagnetic vibrator actuator directly applies force / torque to the rotor without contact. The force / torque generated by the electromagnetic vibrator is controlled by an electromagnetic vibrator controller, achieving direct, dynamic, high-precision, and non-contact simulation of complex loads generated during maneuvering flight. This addresses the problems of existing mechanical motion-based simulation devices, such as complex structure, difficulty in control, introduction of additional interference, inability to accurately and dynamically control loads, and difficulty in achieving non-contact loading.

[0008] The technical solution of the present invention is: an aero-engine rotor maneuvering flight simulation device based on non-contact electromagnetic force loading, comprising a rotor tester system and an electromagnetic exciter test system; The rotor test system includes a rotor assembly, a support assembly, and a drive system. The rotor assembly is coaxial and is used to simulate an aero-engine rotor system. The rotor assembly is driven to rotate by the drive system. The support assembly is used to horizontally support both ends of the rotor assembly. The electromagnetic vibrator experimental system includes at least two electromagnetic vibrator actuators and an electromagnetic vibrator controller. Each electromagnetic vibrator actuator includes a bearing housing and a stator assembly. The bearing housing is used to mount the stator assembly, which is coaxially and non-contactly fitted onto the outer diameter of the drum in the rotor assembly. Based on the principle of electromagnetic induction, the stator assembly generates a radial adsorption force on the drum at its corresponding mounting location when energized. A displacement sensor is installed inside the stator assembly to measure the displacement of the drum at its mounting location in real time and transmit the data to the electromagnetic vibrator controller. The electromagnetic vibrator controller is electrically connected to the electromagnetic vibrator actuators. The controller controls the direction and magnitude of the adsorption force generated by the stator assembly and receives the displacement data measured by the displacement sensor. Based on the displacement data, it adjusts the direction and magnitude of the adsorption force to simulate the force load experienced by the rotor assembly during maneuvering.

[0009] A further technical solution of the present invention is as follows: the rotor assembly includes a first-stage compressor disk, a rotor front conical wall, a first-stage drum, a second-stage compressor disk, a second-stage drum, a third-stage compressor disk, a third-stage drum, a turbine disk, and a rotor rear conical wall, all coaxially and fixedly connected; wherein the first-stage compressor disk is fitted over the rotor front conical wall, and the first-stage compressor disk, rotor front conical wall, and first-stage drum are sequentially fixedly connected by a first set of fasteners; the first-stage drum, second-stage compressor disk, and second-stage drum are sequentially fixedly connected by a second set of fasteners; the second-stage drum, third-stage compressor disk, and third-stage drum are sequentially fixedly connected by a third set of fasteners; one end of the third-stage drum and turbine disk are sequentially fixedly connected by a fourth set of fasteners; the other end of the turbine disk and the rotor rear conical wall are sequentially fixedly connected by a fifth set of fasteners; the outer ends of the rotor front conical wall and the rotor rear conical wall are rotatably supported by a support assembly.

[0010] A further technical solution of the present invention is: the support assembly includes a front rotor support assembly and a rear rotor support assembly, the front rotor support assembly is used to rotatably support the outer end of the front conical wall of the rotor, and the rear rotor support assembly is used to rotatably support the outer end of the rear conical wall of the rotor.

[0011] A further technical solution of the present invention is: the electromagnetic vibrator actuator has two parts, the first electromagnetic vibrator actuator is installed at the secondary drum, and its stator assembly is coaxially and non-contactly sleeved on the outer diameter of the secondary drum; the second electromagnetic vibrator actuator is installed at the tertiary drum, and its stator assembly is coaxially and non-contactly sleeved on the outer diameter of the tertiary drum.

[0012] A further technical solution of the present invention is: the bottom of the bearing housing is fixed on the test platform, the bearing housing is provided with a horizontally set mounting hole, the stator assembly is installed in the mounting hole, the bearing housing is provided with a junction box, the junction box is used for electrical connection between the electromagnetic vibrator actuator and the electromagnetic vibrator controller, and the stator assembly and displacement sensor are connected inside the junction box.

[0013] A further technical solution of the present invention is: the stator assembly includes: The stator magnetic pole has a ring structure. The outer diameter of the stator magnetic pole matches the inner diameter of the mounting hole of the bearing housing. Four sets of magnetic poles are radially convex inward along its inner diameter. The four sets of magnetic poles are evenly distributed around the inner diameter of the stator magnetic pole at 90° intervals. Each set of magnetic poles includes a central large magnetic pole and two small magnetic poles symmetrically located on both sides of the large magnetic pole. The stator coil is set up with four sets of magnetic poles. The stator coil is wound on both the large and small magnetic poles of each set of magnetic poles. The stator coil is electrically connected to the junction box. The upper pressure plate and the lower pressure plate are coaxially mounted on the outer edges of both sides of the stator magnetic pole. They are fixedly connected to the axial limiting boss at one end of the bearing seat mounting hole by a set of fasteners that pass through the upper pressure plate, the stator magnetic pole and the lower pressure plate in sequence. It also includes two sensor brackets, which are coaxially mounted on the inner edges of both sides of the stator magnetic poles. The side of the sensor bracket facing the stator magnetic poles has an inner groove for corresponding cooperation with the four sets of magnetic poles. The outer sides of the large and small magnetic poles of each set of magnetic poles are embedded in the inner groove of the sensor bracket. The two sensor brackets are fixedly connected by a set of fasteners. The sensor brackets have multiple sensor mounting holes along the radial direction for mounting displacement sensors.

[0014] A further technical solution of the present invention is: the electromagnetic exciter controller includes a signal processing unit, a control unit, a power amplifier, and a human-machine interface; The system includes a signal processing unit for acquiring displacement signals from the displacement sensor, processing the data, and transmitting the processed displacement signals to the control unit; a control unit for receiving and processing the displacement signals from the signal processing unit to generate voltage signals corresponding to the four sets of stator coils on the magnetic poles; a power amplifier for receiving the voltage signals from the control unit, amplifying them, and outputting a precisely controllable current to the corresponding stator coils; and a human-machine interface for setting the target parameters of the test, displaying the system status, and test data. The target parameters include target eccentric voltage, target force, target torque, and static / dynamic rotor assembly eccentricity.

[0015] A further technical solution of the present invention is as follows: by energizing the stator coil on a certain set of magnetic poles in the electromagnetic vibrator actuator, an electromagnetic attraction force in the corresponding direction is generated on the drum at the installation location. The magnitude of the attraction force is adjusted by changing the current in the stator coil. The direction of the attraction force on the drum is changed by switching the energization of the stator coils on the four sets of magnetic poles. When the electromagnetic attraction forces applied by the two electromagnetic vibrator actuators are in the same direction, a resultant force is generated on the rotor assembly to simulate the unidirectional overload force generated by diving and climbing. When the electromagnetic attraction forces applied by the two electromagnetic vibrator actuators are in opposite directions, a torque is generated on the rotor assembly to simulate the gyroscopic torque or disturbance generated by rolling and yaw.

[0016] A further technical solution of the present invention is as follows: the power amplifier includes four operating modes: mode I is the energy absorption state, mode II is the first natural freewheeling state, mode III is the energy feedback state, and mode IV is the second natural freewheeling state; when the current of the stator coil is lower than the set current, the power amplifier will alternate between mode I and mode II to gradually increase the stator coil current to the set current value; when the current of the stator coil is higher than the set current, the circuit will alternate between mode III and mode IV to gradually decrease the stator coil current to the set current value.

[0017] A test method for simulating the rotor maneuvering flight of an aircraft engine using the aforementioned simulation device includes the following steps: Start the rotor tester system, and the motor in the drive system will drive the rotor assembly to rotate to the predetermined operating speed; Set the target parameters for the test in the electromagnetic vibrator controller; The closed-loop control function of the electromagnetic vibrator controller is activated. The displacement sensor monitors the rotor assembly displacement in real time and transmits it to the signal processing unit for processing. After processing, the signal processing unit transmits the displacement information to the control unit. The control unit compares the current displacement information with the set target parameters and calculates the error. Based on the error and the preset closed-loop control algorithm, it generates a control voltage signal and sends it to the power amplifier. The power amplifier converts the control voltage signal into a precise and controllable stator coil drive current, which generates a non-contact electromagnetic attraction force on the rotor assembly through the stator magnetic poles. The closed-loop control of the electromagnetic exciter controller is continuously and dynamically carried out. By setting different target parameters, multiple sets of tests are conducted to realistically simulate the dynamic loads borne by the rotor system of the aircraft engine during dive, climb, roll, and yaw. The vibration displacement of the rotor assembly during the test was measured by an external vibration measurement system, providing reference data for the subsequent optimization design of the rotor system.

[0018] The beneficial effects of this invention are: This invention discloses a non-contact electromagnetic force loading-based aero-engine rotor maneuvering flight simulation device and method. The device simulates the normal rotation of an aero-engine rotor system using a rotor test system, and simulates the force loads experienced by the rotor system during maneuvering flight using an electromagnetic vibrator test system. The electromagnetic vibrator actuator in the electromagnetic vibrator test system of this invention generates a magnetic field that applies force / torque directly to the rotor assembly (such as the drum structure) without contact. Through the closed-loop control function of the electromagnetic vibrator controller, the error between the real-time displacement of the rotor assembly and the set target value is compared and adjusted in a timely manner, thereby accurately simulating the real dynamic response of the rotor system under maneuvering conditions.

[0019] Based on the principle of electromagnetic induction, this invention completely eliminates the existing mechanical motion platform, thereby fundamentally eliminating the friction, additional mass, additional inertia, additional stiffness, and additional damping interference caused by mechanical motion, and ensuring the authenticity of the rotor system's dynamic response.

[0020] This invention precisely adjusts the current in the stator coil of the electromagnetic vibrator actuator through an electromagnetic vibrator controller, enabling real-time, independent, and high-precision control of the electromagnetic force vector and torque applied to the rotor assembly. This control method has a fast response speed and is particularly adept at simulating rapidly changing, high-frequency transient loads during maneuvering flight.

[0021] The present invention has a simple structure, eliminating the need for large turntables, multi-link mechanisms, lifting / rotating platforms and other complex mechanical systems. The structure of the test device is greatly simplified, significantly reducing the difficulty and cost of design, manufacturing, installation, debugging and maintenance.

[0022] By configuring the electromagnetic vibrator controller's commands (target eccentric voltage, target force, target torque, static / dynamic rotor assembly eccentricity, etc.) through software, it can flexibly simulate load modes under various maneuvering flight scenarios. It can simulate unidirectional overloads generated by dives and climbs using unidirectional force, simulate gyroscopic torques or disturbances generated by rolls and yaws using torque, and simulate complex coupled maneuvering flight environments using combined forces / torques. The electromagnetic vibrator controller can simultaneously control multiple electromagnetic vibrator actuators. The stator coils on the four sets of magnetic poles in each electromagnetic vibrator actuator can be controlled in combination or individually to achieve accurate application of force or torque.

[0023] This invention monitors the displacement information of the rotor assembly in real time by setting displacement sensors in two sensor brackets. Based on the real-time feedback of the high-precision displacement sensors and combined with the closed-loop control algorithm of the electromagnetic exciter controller, the electromagnetic adsorption force is dynamically adjusted, so that the rotor displacement accurately tracks the set target load, ensuring the accuracy and stability of the simulation.

[0024] This invention provides a highly controllable and cost-effective experimental method for studying the dynamic characteristics (such as vibration response, stability, and support load changes) of high-maneuverability and high-agility aero-engine rotor systems under complex maneuvering flight environments, which is close to the real load environment and provides key data support for the optimized design of engine rotor systems. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the structure of an aero-engine rotor maneuvering flight simulation device based on non-contact electromagnetic force loading (the electromagnetic exciter controller and drive system are not shown). Figure 2 This is a cross-sectional view of the rotor testing system and the two electromagnetic vibrator actuators installed in conjunction with it in this invention. Figure 3 This is an exploded view showing the cooperation between the rotor assembly and the support assembly in the rotor testing system of this invention; Figure 4 for Figure 3 A sectional view; Figure 5 This is a schematic diagram of the structure of the secondary drum in this invention; Figure 6 This is a schematic diagram of the three-stage drum in this invention; Figure 7 This is a schematic diagram of the overall structure of the electromagnetic vibrator actuator in this invention; Figure 8 This is a cross-sectional view of the electromagnetic vibrator actuator in this invention; Figure 9 This is a schematic diagram of the stator assembly structure in this invention; Figure 10 This is an exploded view of the electromagnetic vibrator actuator in this invention; Figure 11 This is a structural diagram of the upper pressure plate in this invention; Figure 12 This is a structural diagram of the lower pressure plate in this invention; Figure 13 This is a structural diagram of the sensor bracket in this invention; Figure 14 This is a schematic diagram of the four operating modes of the three-level switching power amplifier in the electromagnetic exciter controller of this invention; Figure 15 The vibration response curve of the rotor assembly when there is no eccentric voltage (Ux=0, Uy=0); Figure 16 Vibration response curve of rotor assembly when eccentric voltage Uy = +1.6V is set in the vertical direction; Figure 17 Vibration response curve of rotor assembly when the eccentric voltage Uy = -1.6V is set in the vertical direction; Figure 18 Vibration response curve of rotor assembly when the eccentric voltage Ux = +1.6V is set in the horizontal direction; Figure 19 Vibration response curve of rotor assembly when the eccentric voltage Ux = -1.6V is set in the horizontal direction; Figure 20 Vibration response curves of the rotor assembly when the eccentric voltage Uy=+1.2V is set in the vertical direction and the eccentric voltage Ux=+1.2V is set in the horizontal direction; Figure 21 The vibration response curves of the rotor assembly are shown when the eccentric voltage Uy = -0.8V is set in the vertical direction and the eccentric voltage Ux = +1.0V is set in the horizontal direction.

[0027] In the diagram: 1. Rotor assembly; 11. First-stage compressor disc; 12. Rotor front cone wall; 13. First-stage drum; 14. Second-stage compressor disc; 15. Second-stage drum; 16. Third-stage compressor disc; 17. Third-stage drum; 18. Turbine disc; 19. Rotor rear cone wall; 2. Support assembly; 21. Front support assembly; 211. Rotor front support; 212. Front pivot spoke; 213. Front pivot connector; 214. Front pivot bearing bushing; 215. Front pivot ball bearing; 216. Front pivot squirrel cage elastic support; 22. Rear support assembly; 221. Rotor rear support. 222. Rear pivot plate; 223. Rear pivot squirrel cage elastic support; 224. Rear pivot roller bearing; 3. Electromagnetic vibrator actuator; 31. Bearing housing; 32. Junction box; 33. Stator pole; 331. Large pole; 332. Small pole; 34. Stator coil; 35. Upper pressure plate; 36. Lower pressure plate; 37. Sensor bracket; 371. Sensor mounting hole; 372. Internal groove; 38. First hexagon socket screw; 39. Second hexagon socket screw; 3-1. First electromagnetic vibrator actuator; 3-2. Second electromagnetic vibrator actuator; 4. Test platform. Detailed Implementation

[0028] 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, and 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.

[0029] Example 1: This embodiment provides an aero-engine rotor maneuvering flight simulation device based on non-contact electromagnetic force loading. This device is used to accurately simulate the dynamic characteristics of aero-engine rotor systems under complex maneuvering flight environments, and solves the defects of existing maneuvering flight simulation devices based on mechanical motion platforms, such as complex structure, difficult control, introduction of additional interference (friction, additional mass / stiffness / damping), inability to accurately and dynamically control loads (especially high-frequency transient loads), and difficulty in achieving non-contact loading.

[0030] like Figure 1 As shown, the device includes a rotor testing system and an electromagnetic vibrator testing system. The rotor testing system includes a rotor assembly 1, a support assembly 2, and a drive system. The electromagnetic vibrator testing system includes at least two electromagnetic vibrator actuators 3 and an electromagnetic vibrator controller.

[0031] In the rotor test system, rotor assembly 1 is coaxial and is used to simulate a real aero-engine rotor system. Its structure is the same as that of the aero-engine rotor system to be tested. Rotor assembly 1 is driven to rotate by a drive system. Support assembly 2 has two sets, including a front rotor support assembly 21 and a rear rotor support assembly 22, which are used to support the two ends of rotor assembly 1 for horizontal rotation, respectively.

[0032] Specifically, such as Figure 2-4 As shown, the rotor assembly 1 includes a first-stage compressor disk 11, a rotor front conical wall 12, a first-stage drum 13, a second-stage compressor disk 14, a second-stage drum 15, a third-stage compressor disk 16, a third-stage drum 17, a turbine disk 18, and a rotor rear conical wall 19, all coaxially and fixedly connected. One end of the rotor front conical wall 12 is a cylindrical structure, and the other end has a conical wall section. A connecting flange is provided at the end of the conical wall section. The first-stage compressor disk 11 is fitted over the rotor front conical wall 12, and the connecting flange of the first-stage compressor disk 11 contacts the connecting flange of the rotor front conical wall 12. Simultaneously, one end of the first-stage drum 13 is connected to the first-stage compressor disk 11. The first-stage compressor disk 11, the rotor front conical wall 12, and the first-stage drum 13 are sequentially fixedly connected by a first set of fasteners, which are evenly distributed around the circumference of the joint. The other end of the first-stage compressor drum 13 is connected to the second-stage compressor disk 14. The end of the second-stage compressor disk 14 facing away from the first-stage compressor drum 13 is connected to one end of the second-stage compressor drum 15. The first-stage compressor drum 13, the second-stage compressor disk 14, and the second-stage compressor drum 15 are sequentially and securely connected by a second set of fasteners, which are evenly distributed around the joint. The other end of the second-stage compressor drum 15 is connected to one end of the third-stage compressor disk 16. The other end of the third-stage compressor disk 16 is connected to one end of the third-stage compressor drum 17. The second-stage compressor drum 15, the third-stage compressor disk 16, and the third-stage compressor drum 17 are sequentially and securely connected by a third set of fasteners, which are evenly distributed around the joint. The other end of the third-stage compressor drum 17 is connected to one end of the turbine disk 18 and is secured by a fourth set of fasteners around the joint surface. The other end of the turbine disk 18 is connected to the inner side of the rotor rear conical wall 19 by a fifth set of fasteners along the mating surface. The outer end of the rotor rear conical wall 19 is a cylindrical structure. The outer end of the rotor front conical wall 12 is rotatably supported by the front support assembly 21. The outer end of the rotor rear conical wall 19 is rotatably supported by the rotor rear support assembly 22.

[0033] Each component of rotor assembly 1 has a connecting flange at its mating points, which is secured by fasteners such as connecting bolts arranged in a circumferential pattern. The secondary drum 15... Figure 5 As shown, the three-stage drum 17 Figure 6 As shown, the connecting flanges at both ends of the two drums are used to achieve a fixed connection, and the cylindrical section in the middle is in non-contact cooperation with the electromagnetic vibrator actuator 3.

[0034] like Figure 2-4As shown, the rotor front support assembly 21 and rotor rear support assembly 22 provide horizontal rotational support for the rotor assembly 1. The rotor front support assembly 21 includes a rotor front support 211, a front pivot plate 212, a front pivot connector 213, a front pivot bearing bushing 214, a front pivot ball bearing 215, and a front pivot squirrel cage elastic support 216. Specifically, the rotor front support 211 is fixed on the test platform 4 and has horizontal mounting through holes. The front pivot plate 212 and the front pivot connector 213 are fixedly installed in the mounting through holes. The rotor front support 211, the front pivot plate 212, and the front pivot connector 213 are radially and axially connected and fixed by bolts. The front pivot connector 213 is used to install the front pivot squirrel cage elastic support 216, and the two are fixedly connected by bolts. The front pivot plate 212 serves to connect the rotor front support 211 and the front pivot connector 213. The front support squirrel cage elastic support 216 serves as a vibration damping support for the rotor assembly 1. A front support ball bearing 215 is interference-fitted into the central inner hole of the front support squirrel cage elastic support 216. A front support bearing bushing 214 is interference-fitted into the inner ring of the front support ball bearing 215. Simultaneously, the front support bearing bushing 214 is axially limited and fitted onto the outer diameter wall of the outer cylindrical section of the rotor's front conical wall 12. Axial limitation is achieved through an annular protrusion on the outer diameter of the rotor's front conical wall 12. The bushing 214 and the outer diameter of the rotor's front conical wall 12 are interference-fitted. The front support ball bearing 215 enables the rotational connection between the front end of the rotor assembly 1 and the rotor front support assembly 21.

[0035] The rotor rear support assembly 22 includes a rotor rear support 221, a rear pivot plate 222, a rear pivot squirrel cage elastic support 223, and a rear pivot roller bearing 224. Specifically, the rotor rear support 221 and the rotor front support 211 have the same structure. The rotor rear support 221 and the rotor front support 211 are arranged opposite each other and fixed on the test platform 4. The rear pivot plate 222 is coaxially fixedly installed in the mounting through hole of the rotor rear support 221. The rear pivot plate 222 and the rear pivot squirrel cage elastic support 223 are coaxially fixedly connected by bolts. The rear pivot roller bearing 224 is press-fitted into the center hole of the rear pivot squirrel cage elastic support 223. The inner ring of the rear pivot roller bearing 224 is inserted through the outer end cylindrical structure of the rotor rear conical wall 19. The two are press-fitted, and the rear pivot roller bearing 224 realizes the rotational connection between the rear end of the rotor assembly 1 and the rotor rear support assembly 22. The rear support squirrel cage elastic support 223 is used to provide vibration damping support for the rotor assembly 1.

[0036] The drive system includes a motor, a frequency converter, and a control computer. The motor output is connected to the outer end of the rotor front cone wall 12 via a drive belt, for example, to drive the rotor assembly 1 to rotate. The frequency converter controls the motor speed, and the control computer sends motor speed control commands to the frequency converter; the structure is not shown in the attached diagram.

[0037] like Figure 1 As shown, the electromagnetic vibrator experimental system includes at least two electromagnetic vibrator actuators 3 and an electromagnetic vibrator controller. In this embodiment, two electromagnetic vibrator actuators 3 are provided, namely a first electromagnetic vibrator actuator 3-1 and a second electromagnetic vibrator actuator 3-2. The first electromagnetic vibrator actuator 3-1 is installed at the secondary drum 15, and the second electromagnetic vibrator actuator 3-2 is installed at the tertiary drum 17. The two electromagnetic vibrator actuators are completely identical in structure except for their size. The difference in size is to adapt to the size of the drum at the installation location.

[0038] The electromagnetic vibrator actuator 3 includes a bearing housing 31 and a stator assembly. The bearing housing 31 supports and mounts the stator assembly, which is coaxially and non-contactly fitted onto the outer diameter of the drum in the rotor assembly 1. Based on the principle of electromagnetic induction, the stator assembly generates a radial electromagnetic attraction force on the drum at its corresponding mounting location when energized. Simultaneously, a displacement sensor is installed within the stator assembly. This sensor measures the displacement of the drum at the mounting location of the stator assembly 1 in real time and transmits the data to the electromagnetic vibrator controller. The electromagnetic vibrator controller and the electromagnetic vibrator actuator are electrically connected. The controller controls the direction and magnitude of the electromagnetic attraction force generated by the stator assembly 1 and receives the displacement data measured by the displacement sensor. Based on the displacement data, the controller adjusts the direction and magnitude of the attraction force to simulate the force load experienced by the rotor assembly 1 during maneuvering.

[0039] Specifically, such as Figures 7-13 As shown, the bottom of the bearing housing 31 is fixed on the test platform 4. The bearing housing 31 has a horizontally set mounting hole, in which the stator assembly is installed. A junction box 32 is fixedly installed on the bearing housing 31 by screws. The junction box 32 is used for electrical connection between the electromagnetic vibrator actuator 3 and the electromagnetic vibrator controller. The stator assembly 32 and the displacement sensor are connected inside the junction box 32.

[0040] The stator assembly specifically includes stator magnetic poles 33, stator coils 34, an upper pressure plate 35, a lower pressure plate 36, and two sensor brackets 37. The stator magnetic poles 33 have a ring-shaped structure, with their outer diameter matching the inner diameter of the mounting holes in the bearing housing 31. Four sets of magnetic poles are radially convex along the inner diameter of the stator magnetic poles 33, evenly distributed at 90° intervals around the inner diameter of the stator magnetic poles 33. Each set of magnetic poles includes a central large magnetic pole 331 and two symmetrically located small magnetic poles 332 on either side of the large magnetic pole 331. The width of the large magnetic pole 331 is greater than the width of the small magnetic poles 332. The large magnetic poles 331 in the four sets are located in the horizontal and vertical directions, arranged in four positions: up, down, left, and right. The stator coil 34 is provided in multiple sets, corresponding to four sets of magnetic poles. The stator coil 34 is wound on the large magnetic pole 331 and the small magnetic pole 332 of each set of magnetic poles. The stator coil 34 is electrically connected to the junction box 32. The stator coil 34 is connected to the power supply in the electromagnetic exciter controller through the junction box 32 and the cable, so as to realize the power supply for the stator coil 34.

[0041] The upper pressure plate 35 and the lower pressure plate 36 are coaxially mounted on the outer edges of the stator magnetic pole 33 on both sides of the axis. They are fixedly connected to the axial limiting boss at one end of the bearing seat 31 mounting hole by a set of fasteners that pass through the upper pressure plate 35, the stator magnetic pole 33 and the lower pressure plate 36 in sequence. In this embodiment, the upper pressure plate 35 has 12 countersunk holes of φ16.5, and the lower pressure plate 36 has 12 M16 threaded holes corresponding to the 12 countersunk holes. Simultaneously, the stator pole 33 also has 12 through holes corresponding to the 12 countersunk holes. The mounting hole of the bearing housing 31 has an axial limiting boss at one end near the lower pressure plate 36. Around the circumference of the limiting boss are 12 M16 threaded holes corresponding one-to-one with the threaded holes on the lower pressure plate 36. The stator pole 33 and the lower pressure plate 36 are located within the mounting hole of the bearing housing 31. The end face of the lower pressure plate 36 contacts the axial limiting boss. The upper pressure plate 35, stator pole 33, and lower pressure plate 36 are sequentially connected to the boss of the bearing housing 31 using 12 first hexagon socket head cap screws 38, and then secured with nuts that mate with the screws. To facilitate disassembly of the two pressure plates, each pressure plate has 4 set screw holes.

[0042] Two sensor brackets 37 are coaxially mounted on the inner edges of the stator magnetic poles 33 on both sides of the axis. Each sensor bracket 37 has a 3mm deep groove on the side facing the stator magnetic poles, designed to mate with the four sets of magnetic poles. The grooves are designed to match the width of the large magnetic pole 331 and the small magnetic pole 332, ensuring that the outer sides of both the large and small magnetic poles 331 and 332 of each set are embedded in the grooves of the sensor brackets. The two sensor brackets 37 are fixedly connected by a set of fasteners. Specifically, as shown... Figure 13As shown, each of the sensor brackets 37 on the left side of the stator magnetic pole 33 has four φ8.5 countersunk holes. The sensor bracket 37 on the right side has four threaded holes corresponding to the four countersunk holes on the left side of the sensor bracket 37. The two sensor brackets 37 are connected by four second hexagon socket screws 39 and their nuts. The four countersunk holes on the left side of the sensor bracket 37 are evenly distributed at 90° intervals. Figure 13 The diagram shows the sensor bracket 37 on the left. The only difference between the left and right sensor brackets 37 is the through hole for the second hexagon socket screw 39. The left sensor bracket 37 has a countersunk through hole, while the right sensor bracket 37 has a screw hole. The shank of the second hexagon socket screw 39 is located within the gap between two adjacent small magnetic poles 332, axially penetrating the stator magnetic pole 33. The sensor bracket 37 has four radial holes at its four corners, serving as sensor mounting holes 371. These holes correspond to the positions of the four large magnetic poles 331, and displacement sensors are installed within them. Eight eddy current displacement sensors are respectively located within the eight sensor mounting holes 371 of the two sensor brackets 37. The stator assembly of the first electromagnetic vibrator actuator 3-1 is coaxially and non-contactly fitted onto the outer diameter of the second-stage drum 15, and the stator assembly of the second electromagnetic vibrator actuator 3-2 is coaxially and non-contactly fitted onto the outer diameter of the third-stage drum 17. This allows the second-stage drum 15 to rotate within the stator assembly of the first electromagnetic vibrator actuator 3-1, and the third-stage drum 17 to rotate within the stator assembly of the second electromagnetic vibrator actuator 3-2, when the rotor assembly rotates. Vibration displacement measurements at the second-stage drum 15 and the third-stage drum 17 in the rotor system are achieved using eight eddy current displacement sensors. These eddy current displacement sensors can accurately, continuously, and linearly acquire displacement information at the drums. Taking the displacement measurement of the second-stage drum 15 as an example, the eddy current displacement sensor measures the average position of the journal center of the second-stage drum 15 and sets this position as the reference center. Without control force, the rotor system is in a symmetrical equilibrium state, avoiding additional forces introduced by installation errors.

[0043] Specific parameter design: Taking the first electromagnetic vibrator actuator 3-1 on the left side installed at the secondary drum 15 as an example, the diameter of the secondary drum 15 is 261mm, and the design air gap length on one side is 0.8mm. Based on this, the inner diameter of the stator magnetic pole 33 is determined to be 261.8mm, and the width of the stator magnetic pole 33 is 50mm. The stator magnetic pole 33 is formed by cutting, stacking, and welding 0.2mm thick silicon steel sheets. During processing, the key dimensional tolerances and coaxiality requirements must be strictly guaranteed. Taking two sets of magnetic poles in the vertical direction as an example, when a current of 2A is simultaneously applied to their stator coils, the magnetic poles generate two forces of opposite directions and the same magnitude of 2000N on the rotor, with a resultant force of zero, and the rotor is in a balanced state. When a current of 4A is applied to the upper magnetic pole coil and a current of 0A is applied to the lower magnetic pole coil, the rotor experiences an upward resultant force of 4000N. The force principle in the horizontal direction is the same. Each set of magnetic poles consists of a large central pole and two smaller lateral poles, with all three pole coils energized. The upper pressure plate 35 and lower pressure plate 36 are 15mm thick, machined to ensure critical dimensional tolerances, and chemically blackened to improve corrosion and wear resistance. The two sensor supports are 18mm thick, machined to ensure consistent depth with the stator pole insertion area (3mm slot depth) and adherence to critical dimensional tolerances, and brightly anodized. Considering the rotor's weight and shaft bending, a subcritical speed (e.g., 1300 rpm) is selected as the initial centering speed for the rotor system to establish a precise loading reference. At this speed, rotor vibration is minimal and stable.

[0044] The electromagnetic vibrator controller, as the control part of the entire device, includes a signal processing unit, a control unit (such as a PLC or a dedicated controller), a power amplifier, and a human-machine interface.

[0045] The system includes a signal processing unit for acquiring displacement signals from displacement sensors, processing the data, and transmitting the processed displacement signals to the control unit. The control unit outputs voltage signals based on the set target eccentricity voltage and processes the displacement signals from the signal processing unit to generate voltage signals corresponding to the four sets of stator coils on the magnetic poles. The power amplifier receives the voltage signals from the control unit, amplifies them, and outputs a precisely controllable current to the corresponding stator coils. The human-machine interface is used to set the target parameters of the test, display the system status, and test data. The target parameters include the target eccentricity voltage, target force, target torque, and static / dynamic rotor assembly eccentricity.

[0046] Specifically, the signal processing unit amplifies weak sensor signals through signal conditioning, filters and reduces noise to eliminate high-frequency electromagnetic interference, linearizes to compensate for the nonlinear characteristics of the eddy current sensor, corrects errors caused by ambient temperature drift, and outputs a high-precision, interference-resistant standard displacement signal to the control unit. The control unit typically includes a PLC or a dedicated controller with a built-in closed-loop control algorithm. It receives real-time rotor displacement signals, performs calculations, and generates corresponding voltage signals. The power amplifier is one of the key components in the electromagnetic vibrator controller system. It converts the voltage signal calculated and output by the control unit into a control current for the stator coil 34, thereby generating electromagnetic force. In this embodiment, the power amplifier is specifically a three-level switching power amplifier, determined based on the relationship between the coil current and a given reference current signal. Figure 14 As shown, the power amplifier includes four operating modes: Mode I is energy absorption mode, Mode II is the first natural freewheeling mode, Mode III is energy feedback mode, and Mode IV is the second natural freewheeling mode. When the stator coil current is lower than the set current, the power amplifier will alternate between Mode I and Mode II, with the output voltage ranging from 0 to + U in A unipolar pulse voltage gradually increases the current in stator coil 34 to a set current value. When the current in stator coil 34 exceeds the set current, the circuit will alternate between mode III and mode IV, and the output voltage will be - U in A unipolar pulse voltage down to 0 gradually reduces the current in stator coil 34 to the set current value.

[0047] The electromagnetic vibrator controller energizes the stator coil 34 on a specific set of magnetic poles in the electromagnetic vibrator actuator, generating an electromagnetic attraction force in the corresponding direction on the drum where the actuator is installed. The magnitude of the electromagnetic attraction force is adjusted by changing the current in the stator coil 34. By switching the energization of the stator coil 34 on all four sets of magnetic poles, the direction of the attraction force on the drum can be changed.

[0048] In this embodiment, by independently or collaboratively controlling the magnitude and direction of the stator coil current of the two electromagnetic vibrator actuators, the following can be achieved: when the electromagnetic attraction forces applied by the two electromagnetic vibrator actuators are in the same direction, a resultant force (acting horizontally, vertically, or obliquely) is generated at a specific position on the rotor, simulating the unidirectional overload force generated by maneuvers such as dives and climbs. The function of the two electromagnetic vibrator actuators is to control the electromagnetic attraction force applied to the rotor assembly 1 by adjusting the current. When the electromagnetic forces applied by the two electromagnetic vibrator actuators are in opposite directions, a torque is generated on the rotor assembly 1, simulating the gyroscopic torque or disturbance generated by maneuvers such as rolls and yaws. By independently controlling the horizontal and vertical components of the two electromagnetic vibrator actuators, forces or combinations of forces and torques in any direction can be synthesized to simulate complex coupled maneuvering flight environments.

[0049] Example 2 This embodiment provides a test method for simulating the rotor maneuvering flight of an aircraft engine using the simulation device described in the embodiment. The method includes the following steps: Start the rotor testing system, and the motor in the drive system will rotate the rotor assembly to the predetermined operating speed. Considering the rotor's own weight and shaft bending, a subcritical speed (e.g., 1300 rpm) is selected as the initial centering speed to establish an accurate loading reference. At this speed, the rotor vibration is small and stable.

[0050] Set the target parameters for the test in the electromagnetic exciter controller. Specifically, set the target maneuvering flight load parameters through the human-machine interface. The target parameters are expressed in one or a combination of the following forms: 1) The force of a specific direction and magnitude to be applied to the rotor assembly ( F x , F y The desired torque to be applied to the rotor assembly in a specific direction and magnitude. M z ); 2) The static or dynamic eccentricity of the rotor assembly at a specific monitoring location (e.g., the secondary drum 15). D x , D y This eccentricity is an equivalent representation of the maneuvering flight load.

[0051] 3) Desired eccentric voltage command ( U x , U y (The electromagnetic vibrator controller internally converts voltage commands into corresponding force or displacement settings, and there is a corresponding relationship between eccentric voltage commands and eccentricity.)

[0052] x Represents a horizontal quantity. y Represents a vertical measurement. D x The target eccentricity represents the horizontal direction. D y The target eccentricity in the vertical direction. U x The target eccentric voltage represents the horizontal direction. U y This represents the target eccentricity in the vertical direction. In practical operation, for example, the additional centrifugal load generated by the simulated maneuvering flight is equivalent to the offset of the desired rotor secondary drum 15 journal center relative to the rotor system reference center, i.e., the target eccentricity. Dx , D y This target value can be set to a specific value through the electromagnetic exciter controller. D x , D y ) or equivalent target eccentric voltage command ( U x , U y (Built-in calibration relationship of electromagnetic exciter controller).

[0053] The closed-loop control function of the electromagnetic vibrator controller is activated: the displacement sensor monitors the rotor assembly displacement in real time, such as the transient vibration displacement signal of the 15th journal of the secondary drum, to obtain the actual eccentric position (dx, dy), and transmits it to the signal processing unit for processing. After processing, the signal processing unit transmits the precise displacement information to the control unit. The control unit then combines the current displacement information (dx, dy) fed back by the sensor with the set target parameters (force / torque / displacement / voltage, for example)... D x , D y / U x , U y Compare and calculate the error () e x , e y ), and then based on the error ( e x , e y The control voltage signal is generated through a preset closed-loop control algorithm (such as PID). V Cx , V Cy ), control voltage signal ( V Cx , V Cy The power amplifier drives a three-level switching power amplifier, which converts the control voltage signal into a precise and controllable stator coil drive current. This current generates a non-contact electromagnetic attraction force through the stator magnetic poles, acting on the rotor assembly.

[0054] The power amplifier used in this embodiment is a voltage-current type three-level switching power amplifier, mainly composed of a PI controller, a PWM modulator, a power main circuit, and a current feedback loop. This amplifier has energy absorption (output + U in ), Natural Continuous Flow (Output 0), Energy Feedback (Output - U inThe amplifier continuously compares the actual coil current in various operating modes, such as ) I actual ) and the reference current command determined by the control voltage ( I ref ): like I actual < I ref Then, the "Energy Absorption" and "Natural Continuation" modes are used alternately (increasing the duty cycle), outputting 0 to + U in The voltage causes the coil current to rise rapidly to the reference value.

[0055] like I actual > I ref Then, alternately use the "energy feedback" and "natural flow" modes (increase the duty cycle), output - U in When the voltage drops to 0, the feedback mode forces the coil current to drop rapidly to the reference value.

[0056] Through the high-speed and precise switching of the above modes, high dynamic and low-ripple precise control of the stator coil drive current is achieved. The precisely controlled coil current generates a controllable magnetic field in the magnetic poles of the electromagnetic vibrator actuator, which in turn induces a precise and controllable non-contact electromagnetic force on the ferromagnetic component of the rotor secondary drum 15. F x , F y This force acts directly on the rotor system, dynamically adjusting the actual position of the secondary drum journal 15. The high efficiency and fast current tracking capability of the three-level switching power amplifier is the key guarantee for this system to achieve high-precision, high-dynamic load simulation.

[0057] The closed-loop control of the electromagnetic vibrator controller is continuously and dynamically implemented, allowing the electromagnetic force acting on the rotor assembly during rotation to track and simulate the set maneuvering flight loads in real time, thereby stimulating the rotor system's realistic dynamic response under simulated maneuvering conditions. Specifically, the actual eccentricity position of the secondary drum journal 15 ( d x , d y It can dynamically track and stabilize at the set target eccentricity position in real time and with high precision. D x , D y On the ), the dynamic effects of the additional centrifugal load during maneuvering flight on the rotor system were simulated in an equivalent and high-fidelity manner.

[0058] For the rotor test system, a vibration measurement system was selected to measure the vibration of the rotor assembly during the test. This vibration measurement system is a prototype of a main-controlled spring-loaded dry friction damper independently developed by Northwestern Polytechnical University. It is used to collect and record key parameters such as the vibration response signal of the rotor test system under simulated maneuvering flight loads. Displacement sensors are arranged horizontally and vertically on the first-stage compressor disk 11 and turbine disk 18 for real-time vibration displacement, and a velocity sensor is arranged at the drive motor to obtain the real-time velocity of the rotor test system. Using the above vibration measurement system, the feasibility of the proposed aero-engine rotor maneuvering flight simulation device based on non-contact electromagnetic force loading was demonstrated, and the effectiveness of the simulation device of this invention was verified.

[0059] By setting different target parameters (such as eccentric voltage commands of different directions and magnitudes) and conducting multiple sets of tests (such as no load reference, single-direction load, and combined directional load), the device's ability to simulate different maneuvering flight load modes and its rotor response characteristics are verified. The dynamic loads borne by the rotor system of an aircraft engine during dive, climb, roll, and yaw are realistically simulated, and the corresponding characteristics of the rotor system are verified through a vibration measurement system.

[0060] In this embodiment, the vertically upward direction is taken as the positive direction, and the horizontal to the right is taken as the positive direction. A total of seven sets of tests were conducted to verify the effectiveness of the device under seven typical load conditions (based on a no-eccentric voltage condition). The rotor vibration response curves measured by the vibration measurement system under the seven sets of tests are shown below. Figures 15-21 As shown.

[0061] First group of experiments: Turn on the electromagnetic exciter experimental system, no eccentric voltage ( U x =0, U y =0), under this condition, the rotor system vibration response is normal, proving that the electric vibrator experimental system has zero input and no additional interference. Figure 15 As shown, this is the initial state of the rotor without electromagnetic force loading. The first-order quantities in the horizontal and vertical directions of the first-stage compressor disk are similar, the first-order quantities in the horizontal and vertical directions of the turbine disk are similar, and the second-order quantities of each channel are relatively small.

[0062] Second group of experiments: Turn on the electromagnetic vibrator experimental system and set the eccentric voltage in the vertical direction ( U x =0, U y =+1.6V), under this operating condition, verify the ability to simulate loads in the vertical upward direction and the rotor response. For example Figure 16 As shown, with Figure 15In comparison, the first-order quantities of the turbine disk in both the horizontal and vertical directions increase within the rotor speed range. When the rotor speed increases to 1200 rpm, the first-order quantities of the first-stage compressor disk in both the horizontal and vertical directions show a significant upward trend, with the first-order quantity in the vertical direction being greater than that in the horizontal direction. When the rotor speed increases to 1200 rpm, the second-order quantities of each channel also increase significantly.

[0063] The third group of tests: The electromagnetic vibrator experimental system was turned on, and an eccentric voltage was set in the vertical direction (Ux=0, Uy=-1.6V). Under this condition, the ability to simulate loads in the vertically downward direction and the rotor response were verified. Figure 17 As shown, considering the influence of the rotor's own weight, a reverse eccentric voltage is set in the vertical direction, and... Figure 16 In comparison, the first-order quantity of the turbine disk in the vertical direction increases within the rotor speed range, and the difference between the first-order quantity of the turbine disk in the vertical direction and the first-order quantity in the horizontal direction increases.

[0064] Fourth group of experiments: Turn on the electromagnetic vibrator experimental system and set the eccentric voltage in the horizontal direction ( U x =+1.6V, U y =0), under this condition, verify the ability to simulate loads in the horizontal rightward direction and the rotor response. For example Figure 18 As shown, within the rotor speed range, the first-order quantities of the turbine disk in the horizontal and vertical directions increase, while the difference between the first-order quantities in the vertical and horizontal directions of the turbine disk remains almost unchanged.

[0065] Fifth group of experiments: Turn on the electromagnetic vibrator experimental system and set the eccentric voltage in the horizontal direction ( U x =-1.6V, U y =0), under this condition, verify the ability to simulate loads in the horizontal leftward direction and the rotor response. For example Figure 19 As shown, with Figure 18 In contrast, when the eccentric voltage is applied in the opposite direction, the first-order quantities in the horizontal and vertical directions of the first-stage compressor disk and the turbine disk all increase within the rotor speed range. The difference between the first-order quantities in the vertical and horizontal directions of the first-stage compressor disk increases, as does the difference between the first-order quantities in the vertical and horizontal directions of the turbine disk. When the rotor speed increases to 1200 rpm, the second-order quantities in each channel increase significantly.

[0066] Group 6 Experiment: Turn on the electromagnetic vibrator experimental system and set the eccentric voltage in the vertical direction. U y =+1.2V, eccentric voltage set in the horizontal direction U x =+1.2V, verifying the simulation capability of combined load in the oblique upper right direction and the rotor response. For example Figure 20 As shown, when the rotor speed increases to 1200 rpm, the first-order vertical magnitude of the first-order compressor disk increases abruptly. This embodiment has a significant impact on the vibration response at the compressor disk.

[0067] Group 7 Experiment: Turn on the electromagnetic vibrator experimental system and set the eccentric voltage in the vertical direction. U y =-0.8V, eccentric voltage set in the horizontal direction U x =+1.0V, verifying the simulation capability of combined load in the diagonal downward right direction and the rotor response. For example Figure 21 As shown, within the rotor speed range, the first-order quantities of the turbine disk in both the horizontal and vertical directions increase, while the difference between the first-order quantities in the vertical and horizontal directions remains almost constant; the first-order quantity in the horizontal direction of the first-stage compressor disk is greater than that in the vertical direction, and the eccentric voltage in the horizontal direction has a greater impact.

[0068] By directly simulating the mechanical load (such as centrifugal inertial force) by electromagnetic force, the static eccentric position of the rotor assembly will be changed. At this time, the change in the amplitude of the first-order vibration reflects the change in the equivalent unbalance (such as when the rotor is "pulled" towards the target eccentric position during vertical loading).

[0069] During real engine maneuvering flight, the rotor system may exhibit nonlinear behavior due to high loads. According to the electromagnetic force formula, the force is inversely proportional to the square of the air gap: when the rotor is pulled towards the electromagnet, the air gap decreases, and the electromagnetic force increases faster than linearly. During dynamic rotation, the rotor's displacement in the direction of the electromagnetic force modulates the electromagnetic force, generating a force component with a period of half a revolution (i.e., a second-order quantity). After the rotor support system experiences increased static offset, it may enter the nonlinear stiffness region. The nonlinear restoring force leads to higher harmonics in the response, among which the second-order quantity is the most significant.

[0070] Figures 15-21In the diagram, channel 1 (CH1) refers to the horizontal vibration of the first-stage compressor disk, channel 2 (CH2) refers to the vertical vibration of the first-stage compressor disk, channel 3 (CH3) refers to the horizontal vibration of the turbine disk, and channel 4 (CH4) refers to the horizontal vibration of the turbine disk. When the eccentric voltage is set, the first-order quantities of each channel in the rotor vibration response curve reflect the synchronous vibration caused by rotor mass imbalance, while the second-order quantities reflect the nonlinear response or specific fault characteristics of the rotor system. A vibration measurement system is used to verify and record the vibration displacement of the rotor experimental system under different loads in this experiment. The vibration measurement system selected in this embodiment is a prototype of a main-controlled spring-loaded dry friction damper independently developed by the Northwestern Polytechnical University project team. The prototype has a maximum sampling frequency of 1.25MHz, 16 vibration measurement channels, and can acquire vibration displacement, vibration velocity, vibration acceleration, and other voltage signals, as well as 2 speed signals, 4 analog output signals, and 8 digital switch signals. The vibration measurement system uses photoelectric sensors to determine the rotor speed and the phase of the vibration signal, and eddy current sensors to measure the vibration displacement of the monitoring surface. The voltage signals acquired by each sensor in the vibration measurement system need to be processed by the data acquisition and controller of the vibration measurement system, and then processed by the measurement and control software to achieve the purpose of real-time monitoring of the vibration of the rotor test piece and storing the vibration data.

[0071] This embodiment only changes the force applied by the first electromagnetic vibrator actuator 3-1 on the second stage drum 15, proving the feasibility of the aero-engine rotor maneuvering flight simulation device based on non-contact electromagnetic force loading. If force or torque is to be applied to both the second stage drum 15 and the third stage drum 17 at the same time, the same operation is performed on the second electromagnetic vibrator actuator 3-2 on the right.

[0072] Of the seven sets of tests, the first set showed that the system had no self-excited interference. The second to fifth sets of tests showed that the device could dynamically track single-degree-of-freedom (horizontal / vertical) load commands with high precision. The sixth and seventh sets of tests showed that the device could decouple into multi-dimensional (composite direction) kinematic loads in real time, and the rotor displacement trajectory matched the command vector direction well.

[0073] The experimental results demonstrate that this invention, by precisely controlling the current of the electromagnetic exciter, can non-contactly, dynamically, and with high precision reproduce unidirectional overload, combined overload, and moment load during maneuvering flight, effectively avoiding the inherent defects of mechanical motion platforms such as structural complexity, control difficulties, and the introduction of additional interference. The vibration displacement data of the rotor assembly under different loading conditions recorded by the vibration measurement system during this experiment can provide support for the optimized design of the engine rotor system.

[0074] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An aeroengine rotor maneuver flight simulation device based on non-contact electromagnetic force loading, characterized in that, The application relates to a rotor tester system and an electromagnetic exciter experimental system. The rotor tester system comprises a rotor assembly, a support assembly and a driving system. The rotor assembly is coaxial and used for simulating an aero-engine rotor system, and the rotor assembly is driven to rotate by the driving system; the support assembly is used for horizontally rotating and supporting two ends of the rotor assembly. The electromagnetic excitation experimental system comprises at least two electromagnetic exciter actuators and an electromagnetic exciter controller; the electromagnetic exciter actuator comprises a bearing seat and a stator assembly, the bearing seat is used for mounting the stator assembly, the stator assembly is coaxially and non-contactingly sleeved on the outer diameter of a drum cylinder in the rotor assembly, the stator assembly is used for generating radial adsorption force on the drum cylinder at the mounting position when electrified based on the principle of electromagnetic induction; a displacement sensor is mounted in the stator assembly, the displacement sensor is used for measuring the displacement of the drum cylinder at the mounting position of the stator assembly in real time and transmitting the displacement to the electromagnetic exciter controller; the electromagnetic exciter controller is electrically connected with the electromagnetic exciter actuator, the electromagnetic exciter controller is used for controlling the direction and size of the electromagnetic adsorption force generated by the stator assembly, receiving the displacement data measured by the displacement sensor and adjusting the direction and size of the adsorption force according to the displacement data, so as to simulate the force load of the rotor assembly in flight. The rotor assembly comprises coaxially and fixedly connected first-stage compressor discs, a rotor front cone wall, a first-stage drum cylinder, second-stage compressor discs, a second-stage drum cylinder, third-stage compressor discs, a third-stage drum cylinder, turbine discs and a rotor rear cone wall; wherein the first-stage compressor discs are sleeved on the outer side of the rotor front cone wall, the first-stage compressor discs, the rotor front cone wall and the first-stage drum cylinder are sequentially fixedly connected through a first set of fasteners; the first-stage drum cylinder, the second-stage compressor discs and the second-stage drum cylinder are sequentially fixedly connected through a second set of fasteners; the second-stage drum cylinder, the third-stage compressor discs and the third-stage drum cylinder are sequentially fixedly connected through a third set of fasteners; one end of the third-stage drum cylinder and the turbine discs are sequentially fixedly connected through a fourth set of fasteners; the other end of the turbine discs and the rotor rear cone wall are sequentially fixedly connected through a fifth set of fasteners; and the outer end of the rotor front cone wall and the outer end of the rotor rear cone wall are rotationally supported by the support assembly.

2. The non-contact electromagnetic force loading based aeroengine rotor maneuver flight simulation device according to claim 1, characterized in that, The support assembly comprises a rotor front support assembly and a rotor rear support assembly, the rotor front support assembly is used for rotationally supporting the outer end shaft cylinder part of the rotor front cone wall, and the rotor rear support assembly is used for rotationally supporting the outer end shaft cylinder part of the rotor rear cone wall.

3. The non-contact electromagnetic force loading based aeroengine rotor maneuver flight simulation device according to claim 2, characterized in that, The electromagnetic exciter actuators are two, a first electromagnetic exciter actuator is mounted at the second-stage drum cylinder and its stator assembly is coaxially and non-contactingly sleeved on the outer diameter of the second-stage drum cylinder; and a second electromagnetic exciter actuator is mounted at the third-stage drum cylinder and its stator assembly is coaxially and non-contactingly sleeved on the outer diameter of the third-stage drum cylinder.

4. The non-contact electromagnetic force loading based aeroengine rotor maneuver flight simulation device according to claim 2, characterized in that, The bottom of the bearing seat is fixed on a test platform, the bearing seat is provided with horizontally arranged mounting holes, the stator assembly is mounted in the mounting holes, the bearing seat is provided with a junction box, the junction box is used for electrical connection between the electromagnetic exciter actuators and the electromagnetic exciter controller, and the stator assembly and the displacement sensor are connected in the junction box.

5. The non-contact electromagnetic force loading based aeroengine rotor maneuver flight simulation device according to claim 1, characterized in that, The stator assembly comprises 6. The non-contact electromagnetic force loading based aeroengine rotor maneuver flight simulation device according to claim 1, characterized in that, ​ The stator magnetic pole has a ring-shaped structure, and the outer diameter of the stator magnetic pole is matched with the inner diameter of the mounting hole of the bearing seat, and four groups of magnetic poles are arranged on the inner diameter of the stator magnetic pole in the radial direction; the four groups of magnetic poles are uniformly distributed at an interval of 90 degrees along a circumference of the inner diameter of the stator magnetic pole; each group of magnetic poles comprises a central large magnetic pole and two small magnetic poles symmetrically arranged on both sides of the large magnetic pole; The stator coil is arranged corresponding to the four groups of magnetic poles, and the large magnetic pole and the small magnetic pole of each group of magnetic poles are wound with the stator coil; the stator coil is electrically connected with the junction box; The upper pressing plate and the lower pressing plate are coaxially installed at the outer edges of the two sides of the stator magnetic pole, and are fixedly connected with the axial limiting boss at one end of the bearing seat mounting hole through a set of fasteners in sequence through the upper pressing plate, the stator magnetic pole and the lower pressing plate; And two sensor supports are coaxially installed at the inner edges of the two sides of the stator magnetic pole, and the inner grooves of the sensor supports are arranged on the side facing the stator magnetic pole, and are arranged corresponding to the four groups of magnetic poles; the outer sides of the large magnetic pole and the small magnetic pole of each group of magnetic poles are embedded into the inner grooves of the sensor supports, and the two sensor supports are fixedly connected through a set of fasteners; a plurality of sensor mounting holes are arranged on the sensor supports in the radial direction, and are used for mounting displacement sensors.

7. The non-contact electromagnetic force loading based aeroengine rotor motoring flight simulator of claim 6, wherein, The electromagnetic exciter controller comprises a signal processing unit, a control unit, a power amplifier and a man-machine interface; The signal processing unit is used for collecting displacement signals of the displacement sensors, performing data processing, and transmitting the processed displacement signals to the control unit; the control unit is used for receiving and processing the displacement signals from the signal processing unit, and generating voltage signals corresponding to the control of the stator coils of the four groups of magnetic poles; the power amplifier is used for receiving the voltage signals of the control unit, amplifying and outputting accurately controllable currents to the corresponding stator coils; the man-machine interface is used for setting target parameters of the test, displaying system states and test data; the target parameters include target eccentric voltage, target force, target torque, static / dynamic rotor assembly eccentricity.

8. The non-contact electromagnetic force loading based aeroengine rotor motoring flight simulator of claim 7, wherein, By energizing the stator coil of a certain group of magnetic poles in the electromagnetic exciter actuator, an electromagnetic attraction force in the corresponding direction is generated on the drum cylinder installed thereon; the size of the electromagnetic attraction force is adjusted by changing the current size of the stator coil; the direction of the electromagnetic attraction force on the drum cylinder is changed by switching the energization of the stator coils of the four groups of magnetic poles; when the directions of the electromagnetic attraction forces applied by the two electromagnetic exciter actuators are the same, a resultant force is generated on the rotor assembly, which is used to simulate the unidirectional overload force generated by diving and climbing; when the directions of the electromagnetic attraction forces applied by the two electromagnetic exciter actuators are opposite, a torque is generated on the rotor assembly, which is used to simulate the gyroscopic torque or disturbance generated by rolling and yawing.

9. The non-contact electromagnetic force loading based aeroengine rotor motoring flight simulation apparatus according to claim 7, characterized in that, The power amplifier comprises four working modes, mode I is an energy absorption state, mode II is a first natural freewheeling state, mode III is an energy feedback state, and mode IV is a second natural freewheeling state; When the current of the stator coil is lower than the set current, the power amplifier will work alternately between mode I and mode II, which is used to gradually increase the current of the stator coil to the set current value; when the current of the stator coil is higher than the set current, the circuit will work alternately between mode III and mode IV, which is used to gradually reduce the current of the stator coil to the set current value.

10. A method for testing the rotor dynamic behavior of an aeroengine by using the simulation device of claim 7, characterized in that, The method comprises the following steps: The rotor tester system is started, and the rotor assembly is rotated to a predetermined working rotating speed by the motor in the driving system; The target parameters of the test are set in the electromagnetic exciter controller; The closed-loop control function of the electromagnetic exciter controller is started, the displacement sensor monitors the displacement of the rotor assembly in real time and transmits it to the signal processing unit for processing, the signal processing unit transmits the displacement information to the control unit after processing, the control unit compares the current displacement information with the set target parameters, calculates the error, and generates a control voltage signal according to the error and the preset closed-loop control algorithm and sends it to the power amplifier; the power amplifier converts the control voltage signal into an accurately controllable stator coil driving current, and the non-contact electromagnetic attraction force generated by the stator magnetic pole acts on the rotor assembly; The closed-loop control of the electromagnetic exciter controller is continuously and dynamically carried out, a plurality of tests are carried out by setting different target parameters, and the dynamic load borne by the rotor system when the aircraft engine is in diving, climbing, rolling and yawing is simulated; The vibration displacement of the rotor assembly in the test is measured by the external vibration measurement system, and reference data is provided for subsequent optimization design of the rotor system.

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