Method for prolonging service life of aero-engine service life limiting piece based on data

Abstract

The invention discloses a method for prolonging the service life of an aero-engine service life limiting piece based on data, and the method gives out the process steps of prolonging the service life on the basis of damage data, flight data and design data, so that the operability of the service life prolonging activity of an engine is higher. According to the technical scheme, the method comprises the steps that firstly, the service life prolonging activity process of the service life limiting piece is established; 2, performing statistics / analysis on damage data; 3, carrying out life verification; wherein the establishment process of the first step comprises the following steps: step 1, designing data of life analysis; 2, part development test activities are carried out; step 3, engine development / evidence obtaining test activity; and 4, obtaining service data.

Description

TECHNICAL FIELD

[0001] The present application relates to a life extension activity of life-limited parts / time-limited parts / life control parts of an aero-engine. Based on the damage / maintenance data, design data and flight data of the life-limited parts, modeling analysis and experimental verification are performed on the life-limited parts to determine the extended life of the life-limited parts based on the used (original design data). Life extension of life-limited parts is a technical life management activity in the early use of aero-engines. BACKGROUND

[0002] The traditional method is to use the newly developed aero-engine after obtaining the airworthiness certificate, and then perform overhaul inspection at the first TBO (Time Between Overhaul) or perform non-planned inspection repair due to accidental failure. However, there is usually no planned review activity of life-limited parts during TBO, which may cause potential defects of life-limited parts to be ignored or not found in time, and thus the cause of the defect is not clear and the growth pattern of the defect is not clear. In this case, the defect characteristics and evolution law of the new engine cannot be effectively mastered, which may affect the design improvement of the engine and eventually endanger the flight safety.

[0003] Due to the lack of statistical analysis of engine damage data during TBO, there is a lack of clear defect damage pattern, which brings challenges to the life extension of the engine. Lack of in-depth understanding and tracking of potential problems of the engine during use may lead to uncertainty of life extension decision and difficulties in life extension process. Therefore, for the life management and defect tracking of the engine, more in-depth data analysis and monitoring measures are needed, and potential problems during TBO of the engine should be found and solved in time to ensure the continuous and stable performance of the engine and flight safety. SUMMARY

[0004] The following gives a brief summary of one or more aspects to provide a basic understanding of these aspects. This summary is not an exhaustive overview of all contemplated aspects, and neither is it intended to identify key or essential elements of all aspects nor to delineate the scope of any or all aspects. Its sole purpose is to give a brief overview of some concepts of one or more aspects in a simplified form as a prelude to the more detailed description given later.

[0005] The present application aims to solve the above problems and provides a data-based life extension method for life-limited parts of an aero-engine. Based on damage data, flight data and design data, the life extension process steps are given, making the engine life extension activity more operable. The present application has strong engineering practicability, clear purpose and clear path data.

[0006] The technical scheme of the present application is as follows: the present application discloses a data-based life extension method for life-limited parts of an aero-engine, and the method comprises the following steps:

[0007] Firstly, a life extension process of the life-limited part is established;

[0008] Secondly, damage data is counted and analyzed;

[0009] Thirdly, life verification is performed;

[0010] The first step of establishing the process comprises the following steps:

[0011] Step 1: designing data for life analysis;

[0012] Step 2: developing a test activity for the part;

[0013] Step 3: developing an engine development / forensic test activity;

[0014] Step 4: obtaining service data.

[0015] According to an embodiment of the data-based life extension method for life-limited parts of an aero-engine, the data designed in step 1 comprises operating requirements and performance evaluation, conversion calculation of performance to design parameters, calculation of load, temperature and stress, and life evaluation, wherein the operating requirements and performance evaluation comprise flight tasks and flight task combination / subtasks, including ground operation, engine life parameters and life period performance parameters, and the conversion calculation of performance to design parameters comprises engine performance parameters and secondary flow air system calculation.

[0016] According to an embodiment of the data-based life extension method for life-limited parts of an aero-engine, the test items in step 2 comprise thermal-mechanical tests of the part, bench super-rotation tests of the part and cycle tests.

[0017] According to an embodiment of the data-based life extension method for life-limited parts of an aero-engine, the activity items in step 3 comprise secondary flow pressure and temperature measurement, air flow and metal part temperature measurement, vibration stress measurement, engine performance parameter measurement and engine cycle task test.

[0018] According to an embodiment of the data-based life extension method for life-limited parts of an aero-engine, the service data in step 4 comprises workshop repair data, condition-based repair data and life extension sample data.

[0019] According to an embodiment of the data-based life extension method for life-limited parts of an aero-engine, the second step further comprises the following steps:

[0020] According to the key areas of the part, the types of defects and the data of the defects are counted;

[0021] Establishing the strength model of the damage, simulating and analyzing the expansion or growth of the damage, and establishing the corresponding strength model based on the collected defect data to simulate and analyze the expansion or growth of the damage;

[0022] Giving further bench test / flight cycle test suggestions;

[0023] Giving life extension scheme or suggestion;

[0024] Giving design improvement suggestion, and whether to issue service notice.

[0025] According to an embodiment of the data-based life extension method of the aero-engine life-limited part of the application, the purpose of the life verification review in the third step includes:

[0026] Confirming the correctness of the original life calculation assumption through analysis of all relevant flight data;

[0027] The effectiveness of important changes related to the consumed service life on the original life calculation assumption;

[0028] Continuing to fly to the existing remaining life, evaluating or assessing its potential risks;

[0029] Correcting the original life prediction value by increasing the correction factor to improve the service life.

[0030] According to an embodiment of the data-based life extension method of the aero-engine life-limited part of the application, the factors considered in the life verification review in the third step include: actual flight usage data based on real service tasks, service experience, performance changes, secondary flow changes, and component development test results.

[0031] According to an embodiment of the data-based life extension method of the aero-engine life-limited part of the application, the life analysis in the third step needs the following test results: new part life extension low cycle fatigue cycle test results, and serviced part low cycle fatigue cycle test results, wherein the content of the test results includes: material changes / changes, process changes / changes, additional or extra stress / life calculation and its algorithm and program updates, laboratory evidence, engine control software changes / changes, high cycle fatigue effects not considered in the design process, life management plan and sample part evidence, and suggestions and measures of the local office or safety review committee.

[0032] The present application has the following advantages over the prior art: the present application establishes a damage data analysis model based on actual flight conditions through statistical / analysis activities of engine maintenance data or damage data, and gives a feasible suggestion on whether to continue the cycle test or the bench test. The present application establishes a life extension activity process, records and tracks the defects of key components of the engine and the generation and development process of the defects, effectively controls the life of the key components, and provides reliable data support for the life extension of the life-limited components and the extension of the TBO of the engine. The present application gives design improvement suggestions through the analysis of flight data and design data and damage data, so as to reduce the occurrence probability of engine defects as much as possible.

[0033] Therefore, the present application can have the following advantages:

[0034] In the design and development stage, it is difficult to accurately evaluate the influence of occasional faults or defects (such as thermal corrosion, environmental corrosion, fretting wear, etc.) on the performance of the engine due to the existence of certain boundary conditions in the calculation method. At the same time, due to the difference between the development test and the actual flight scene, the recognition of the defect mode also has certain limitations.

[0035] The present application aims at this problem, and provides timely recording and tracking of defects of key components during the TBO of the engine, and provides reliable data support for the life extension of the life-limited components through statistical analysis of damage defect data. At the same time, the present application also provides suggestions for the design improvement of the life-limited components, promotes the perfection and optimization of the engine design. Through in-depth analysis of the defects, the present application also provides an evaluation on whether to further carry out the bench test, and provides a systematic methodology for the life extension and design improvement of the engine.

[0036] Through the implementation of the present application, the maintenance performance of the engine is improved, and the operating cost of the engine is further reduced. This comprehensive defect management and analysis method helps to improve the reliability and performance of the engine, and at the same time provides important guidance and support for subsequent engine research and development and maintenance work. BRIEF DESCRIPTION OF DRAWINGS

[0037] The above features and advantages of the present application can be better understood after reading the detailed description of embodiments of the present disclosure in conjunction with the following drawings. In the drawings, the components are not necessarily drawn to scale, and the components having similar related properties or features can have the same or similar reference numerals.

[0038] Figure 1 A flowchart of an embodiment of a data-based life extension method for life-limited components of an aero-engine of the present application is shown.

[0039] Figure 2 A schematic diagram of life verification review input and process is shown. DETAILED DESCRIPTION

[0040] The application will be described in detail below in conjunction with the accompanying drawings and specific embodiments. Note that the aspects described below in conjunction with the accompanying drawings and specific embodiments are only exemplary and should not be understood as limiting the scope of protection of the application in any way.

[0041] Figure 1 The flow of an embodiment of the data-based aero-engine life-limited part life extension method of the application is shown. Please see Figure 1 The following is a detailed description of the implementation steps of this embodiment.

[0042] Step 1, establish the life extension activity flow of life-limited parts.

[0043] The establishment of the flow is divided into the following steps 1 to step 4.

[0044] Step 1: Design life analysis data.

[0045] The content of the designed data includes:

[0046] (1) Operation requirements and performance evaluation: flight tasks and flight task merging / subtasks, including ground operation, engine life parameters, life period performance parameters, etc.

[0047] (2) Performance to design parameter conversion calculation: including engine performance parameters, secondary flow air system calculation.

[0048] (3) Load, temperature and stress calculation: including load, pressure, temperature, stress calculation.

[0049] (4) Life evaluation.

[0050] Step 2: Component development test activities.

[0051] Test items include:

[0052] Thermal-mechanical test of parts, this test mainly evaluates the performance of parts under the action of heat or force, simulates the thermal and mechanical stress of the engine under different working conditions, tests the stability and durability of the parts under extreme environments such as high temperature and high pressure, which helps to verify whether the design parameters meet the requirements under actual working conditions, and provides reliability guarantee for actual use;

[0053] Bench super-rotation test of parts, this test is usually used to evaluate the performance and stability of parts under high speed operation, simulates the super-rotation speed condition of the engine during operation on the bench, tests whether the parts can work normally under high load and high speed operation, and evaluates the reliability and safety of the parts under high speed environment;

[0054] Cycling test, cycling test is a test that simulates the actual use of parts, through the simulation of parts in different working conditions, different load cycle operation, to evaluate the durability and performance degradation of parts, cycling test can help to reveal the problems that may occur in the long time running, and provide important reference for extending the life of limited life parts.

[0055] Step 3: Engine development / forensic test activities.

[0056] Activity items include:

[0057] Secondary flow pressure and temperature measurement, this test activity aims to measure the pressure and temperature of the secondary flow in the engine, by monitoring the parameter change of the secondary flow, to evaluate the combustion efficiency and heat energy utilization rate of the engine, to ensure the stability and performance of the engine under high temperature and high pressure;

[0058] Airflow and metal part temperature measurement, by measuring the airflow and metal part temperature of each part in the engine and the surrounding environment, the cooling effect and thermal balance state of the engine under different working conditions can be evaluated. This can reveal the heat distribution of the engine in operation, and provide data support for optimizing the heat dissipation system and improving the performance of the engine;

[0059] Vibration stress measurement, by measuring the vibration characteristics and stress of the engine during operation, the vibration stability and part bearing capacity of the engine under high speed can be evaluated. This helps to find the potential impact of vibration on the engine, to ensure the life and safety of the engine in long time operation;

[0060] Engine performance parameter measurement, by measuring the key engine performance parameters such as thrust, fuel consumption, gas temperature, etc., it can be verified whether the performance index of engine design meets the expected requirements. This helps to evaluate the performance of the engine in actual operation, find problems in time and make adjustment and optimization;

[0061] Engine cycle task test, this test activity aims to simulate the running of the engine under different flight tasks and working conditions, to verify the performance and stability of the engine in actual use. Through cycle task test, the adaptability and reliability of the engine under different loads can be evaluated, which provides important reference for the life extension and use of the engine.

[0062] Step 4: Obtain service data.

[0063] Service data includes workshop repair data, condition-based repair data, life extension sample data.

[0064] Workshop repair data includes but is not limited to:

[0065]

[0066] The visual repair data mainly refers to the damage data of the visual parts.

[0067] The sample item corresponding to the life extension sample data is determined as follows. The sample item is a key part for verifying the life of the engine, which is planned to be used for life examination on the leading engine. The sample part is a part that is completely disassembled to the part level, can be inspected, can be cleaned, and can be subjected to NDT (Non-Destructive Testing). The part should be inspected according to the manual. Other destructive measurements or test tasks may cause the sample part to be in an unusable state, such as hardness measurement, residual stress test, slicing, microstructure analysis, etc. All inspection results must be fed back to the engineering design department. The following table gives the determination cases of the sample item (the number of samples depends on the number of operating engines, but cannot be too small):

[0068] Sample Item Service Life Minimum Number of Samples Sample Item No. 1 X.XX - X.XX Sr (Safe Cycle Service Life) XX Sample Item No. 2 X.XX - X.XX Sr XX Sample Item No. 3 X.XX - X.XX Sr XX

[0069] Second step, statistical analysis of damage data.

[0070] The specific processing steps of the second step are as follows.

[0071] a) According to the key areas of the parts, the defect type and defect data are counted. In this step, first, the parts need to be comprehensively detected and evaluated, and different types of defects such as cracks, wear, corrosion, etc. are counted, and the key data such as the size (area, length, depth) of the defects are recorded. Especially for cracks, physical slicing analysis may be needed to accurately measure the depth and length of the cracks to ensure accurate evaluation of the defects.

[0072] b) Establish a damage intensity model to simulate the expansion or growth of damage. Based on the collected defect data, a corresponding intensity model is established to simulate the expansion or growth of damage. By simulating the damage expansion process under different working conditions, the life tolerance of the life-limited part within and outside TBO is calculated and predicted, providing quantitative basis for engine life extension.

[0073] c) Give suggestions for further bench test / flight cycle test: Based on the analysis results of the damage data, suggestions for further bench test or flight cycle test can be given. These tests can further verify the damage expansion model and results to evaluate the performance stability and life potential of the life-limited part under different working conditions.

[0074] d) Give life extension scheme or suggestion: Based on the analysis of damage data and test results, specific life extension scheme or suggestion is made. This may include adjusting the maintenance plan, improving the design of life-limited parts, optimizing flight operation, etc. to extend the life of life-limited parts and improve the reliability of the engine.

[0075] e) Provide design improvement recommendations and determine whether to issue a service bulletin: Based on the analysis results, propose design improvement recommendations to improve the design performance of life-limited components and extend their service life. Additionally, depending on the circumstances, it may be necessary to consider issuing a service bulletin to notify users to perform relevant inspections or repairs on life-limited components to ensure flight safety.

[0076] Step 3: Conduct lifespan verification.

[0077] Reference Figure 2 As shown, the details of lifetime verification are as follows.

[0078] On the one hand, the purposes of lifetime verification review include:

[0079] (1) The correctness of the original lifetime calculation assumptions was confirmed through the analysis of all relevant flight data;

[0080] (2) The validity of significant changes to the assumptions about the original service life calculation related to the service life already spent;

[0081] (3) Continue flying until the current remaining lifespan, and assess or evaluate its potential risks;

[0082] (4) The original life prediction value is corrected by increasing the correction factor w in order to improve the service life.

[0083] On the one hand, the life verification review must consider the following factors:

[0084] (1) Based on actual flight usage data from real service missions;

[0085] Engineering analysis requires actual mission data recorded by the aircraft flight data recorder and engine data recorder, such as flight time, altitude, speed, engine low-pressure shaft speed N1, engine high-pressure shaft speed N2, temperature, pressure, etc. This data reflects the relationship between the actual engine usage data under real flight missions and the engine design mission data.

[0086] Other data includes environmental information, such as ambient temperature, humidity, dust conditions, wind speed, etc.

[0087] (2) Service experience (parts damage, repair, etc.);

[0088] Life analysis requires reference to the actual usage report of the part, which includes the part's inspection information, repair information, hole inspection damage information, changes made during major overhauls, wear and all serious abnormal information.

[0089] At the same time, the deviation of parts and the use of concessions should also be considered.

[0090] (3) Performance changes (real service data that do not match the performance design assumptions, degradation, etc.);

[0091] Life analysis needs to refer to performance data, including at least engine operating state simulation, performance degradation, performance correction, performance control software updates, etc.

[0092] (4) Secondary flow changes (seal gap degradation during service that does not match the design assumptions, etc.);

[0093] Life analysis needs to refer to secondary flow air system data, including at least engine operating state simulation, secondary flow correction updates, air system control software updates, etc.

[0094] (5) Component development test results (overspeed test, etc.).

[0095] On the one hand, life analysis needs the following test results:

[0096] (1) New part life extension LCF cycle test results: The life extension LCF (low cycle fatigue) cycle test results of new parts are crucial for evaluating the fatigue performance of new parts in actual operation. These test results cover the fatigue performance of the parts under a predetermined number of cycles, which can help determine the design life of new parts and the feasibility of life extension;

[0097] (2) LCF cycle test results of parts in service for the evaluation of residual life and life extension.

[0098] Test results include the following:

[0099] Material changes / alterations: Considering the changes or alterations of the part material during service is crucial for the evaluation of life impact;

[0100] Changes / alterations in the process: Consider changes and updates in the production and maintenance process of the part, which may affect the fatigue performance and life of the part;

[0101] Additional or additional stress / life calculation and its algorithm, program, etc. Update: Update the stress calculation and life prediction algorithm, correct and update according to the latest data and experimental results;

[0102] Laboratory evidence: Including the data results of laboratory tests such as section analysis, flaw detection, inspection, etc., which helps to evaluate the actual damage of the part;

[0103] Engine control software changes / alterations: Consider the impact of changes in engine control software on the fatigue performance and life of the part;

[0104] HCF Effects Not Considered in Design Process: Consider the potential impact of high-cycle fatigue (HCF) on part life, ensuring that different fatigue mechanisms are considered comprehensively;

[0105] Life Management Plan (LMP) and Sample Part Evidence (Sample Part Damage Data): Evaluate sample part damage data and life prediction models to support residual life assessment and life extension decisions;

[0106] Regulatory or Safety Review Board Recommendations and Actions: Consider recommendations and actions from regulatory agencies or safety review boards to ensure that life analysis and life extension strategies comply with relevant regulations and safety standards.

[0107] By integrating the above test results and data, the life status and residual life of the life-limited part can be more accurately evaluated, providing support and basis for developing appropriate life extension solutions. By comprehensively considering data and test results from different aspects, the accuracy and reliability of life analysis can be ensured.

[0108] Although the above methods are illustrated and described as a series of acts, it will be appreciated that the methods are not limited by the order of acts, as some acts can, in accordance with one or more embodiments, occur simultaneously or in different orders with other acts from those illustrated and described herein or in conjunction with other acts not specifically mentioned but nevertheless present in the embodiments described herein.

[0109] The previous description of the disclosure is provided to enable any person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be apparent to those skilled in the art, and the generic principles defined herein can be applied to other variations without departing from the spirit or scope of the disclosure. Thus, the disclosure is not intended to be limited to the examples and designs described herein, but is to be accorded the broadest scope consistent with the principles and novel features disclosed herein.

Claims

1. A data-based method for life extension of a life-limited part of an aeroengine, characterized in that, The method comprises: First, establishing the life extension activity process of the life-limited part; Second, statistical analysis of damage data; Third, life verification; The first step of establishing the process comprises: Step 1: Design life analysis data; Step 2: Component development test activities; Step 3: Engine development / investigation test activities; Step 4: Obtain service data.

2. The data-based aeroengine life limiting part life extension method of claim 1, wherein, The data content of step 1 design includes: operation requirement and performance evaluation, performance to design parameter conversion calculation, load, temperature and stress calculation, life evaluation, wherein the operation requirement and performance evaluation includes flight mission and flight mission merging / subtask, including ground operation, engine life parameter, life period performance parameter, performance to design parameter conversion calculation includes engine performance parameter, secondary flow air system calculation.

3. The data-based aeroengine life limiting part life extension method of claim 1, wherein, Step 2 test items include: thermal-mechanical test of parts, bench super-rotation test of parts, cycle test.

4. The data-based aeroengine life limiting part life extension method of claim 1, wherein, Step 3 activity items include: secondary flow pressure and temperature measurement, air flow and metal part temperature measurement, vibration stress measurement, engine performance parameter measurement, engine cycle mission test.

5. The data-based aeroengine life limiting part life extension method of claim 1, wherein, The service data of step 4 includes workshop repair data, on-condition repair data, life extension sample data.

6. The data-based aeroengine life limiting part life extension method of claim 1, wherein, The second step further comprises: According to the key area of the part, the type and data of defects are counted; Establishing the strength model of damage, simulating the expansion or growth of damage, based on the collected defect data, establishing the corresponding strength model, simulating the expansion or growth of damage; Give further bench test / flight cycle test suggestions; Give life extension scheme or suggestion; Give design improvement suggestion, and whether to issue service notice.

7. The data-based aeroengine life limiting part life extension method of claim 1, wherein, The purpose of life verification review in the third step includes: Through all the relevant flight data analysis, confirm the correctness of the original life calculation assumption; The effectiveness of important changes related to the consumed service life about the original life calculation assumption; Continue to fly to the existing remaining life, evaluate or evaluate its potential risk; Modify the original life prediction value by adding a correction factor to improve the service life.

8. The data-based aeroengine life limiting part life extension method of claim 1, wherein, The factors considered in the third step of life verification review include: actual flight usage data based on real service mission, service experience, performance change, secondary flow change, component development test result.

9. The data-based aeroengine life limiting part life extension method of claim 1, wherein, The life analysis in the third step needs the following test results: new part life extension low cycle fatigue cycle test result, service part low cycle fatigue cycle test result, wherein the test result content includes: material change / alteration, process change / alteration, additional or extra stress / life calculation and its algorithm and program update, laboratory evidence, engine control software change / alteration, high cycle fatigue impact not considered in design process, life management plan and sample evidence, suggestions and measures of local office or safety review committee.

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