A rocket engine test stand spray cooling system

Abstract

This invention relates to a spray cooling system for a rocket engine test stand, comprising a spray ring module and a guide channel module. The spray ring module is located at the wellhead of the test stand, coaxial with the center of the test frame, and is made of seamless stainless steel pipe arranged spirally, threadedly connected to a pre-embedded steel plate in the test stand ground. The guide channel module is located at the bottom of the test stand, including a support frame and a guide channel inclined at the top of the support frame. The guide channel consists of a core area spray structure and a non-core area spray structure. The support frame is welded and fixed to the pre-embedded steel plate in the test stand ground. Both the spray ring module and the guide channel module are connected to an external water source via water pumps and valves. This invention can protect the wellhead foundation from ablation and quickly guide the combustion gases away from the test stand, preventing flames, smoke, and debris from reflecting back and impacting the test stand, damaging the engine and other supporting equipment. This spray cooling system can adapt to the cooling and noise reduction requirements during the testing of rocket engines with different thrust.

Description

Technical Field

[0001] This invention relates to the field of spray cooling system technology, and more specifically to a spray cooling system for a rocket engine test stand. Background Technology

[0002] When liquid rocket engines are tested on the ground, the engine nozzle will generate high temperature, high pressure and high speed gas flow. The mechanical erosion, chemical corrosion and thermal shock caused by the gas jet will affect the civil structure of the test platform. In addition, the aerodynamic noise generated by the gas jet will reach more than 170dB, which will cause great damage to the ground test facilities.

[0003] Currently, traditional test stands mostly use wellhead spray pipes or guide troughs for cooling to reduce flame temperature and gas noise. However, the cooling range of spray pipes is relatively small, and the engine gas flow rate is high, so the sprayed cooling water is usually directly blown away by the gas, resulting in poor wellhead cooling and inability to protect the test stand. Guide troughs are mostly of the type where steel plates are pre-embedded in cement and welded to the housing jacket, and generally require a high-level water tank at an altitude much higher than the guide trough. This requires a large amount of water resources, has a long construction period, and is costly, making it difficult to adapt to the current rapid development of commercial aerospace. Furthermore, cement platforms are prone to producing cement and stone debris after long-term use, which seriously affects the safety of engine testing. Summary of the Invention

[0004] This invention addresses the technical problems existing in the prior art by providing a spray cooling system for a rocket engine test stand.

[0005] The technical solution of the present invention to solve the above-mentioned technical problems is as follows: A rocket engine test stand spray cooling system includes a spray ring module and a guide channel module. The spray ring module is located at the wellhead of the test stand, coaxial with the center of the test frame, and includes a spray water ring, which is threadedly connected to a pre-embedded steel plate on the test stand ground. The guide channel module is located at the bottom of the test stand and includes a support frame and a guide channel inclined on top of the support frame. The support frame is welded and fixed to the pre-embedded steel plate on the test stand ground. The guide channel consists of a core area spray structure and a non-core area spray structure. Both the spray ring module and the guide channel module are connected to an external water source through water pumps and valves.

[0006] The beneficial effects of this invention are: 1. A thermal protection spray ring module is installed at the wellhead of the test bench. The spray water ring can directly spray cooling water to interact with the high-temperature gas. Through gas-liquid phase change heat, the internal temperature of the gas is reduced, achieving the purpose of cooling. Moreover, the cooling range is large, which can protect the wellhead foundation from ablation. 2. An inclined guide channel is installed at the bottom of the test stand, and the core and non-core areas of the guide channel are supplied with water by independent pipelines. The inclined guide channel can use its inclined structure to quickly and smoothly guide the high temperature and high speed gas jet generated during the rocket engine test away from the test stand, preventing flames, smoke and debris from reflecting back and impacting the test stand, damaging the engine and other supporting equipment; while the independent pipeline water supply can adapt to the water supply flow during the test of engines with different thrust. 3. The cooling water for the spray system is supplied by pumps, and the flow rate is controlled by valves, eliminating the need to build an elevated water tank; 4. This spray cooling system can adapt to the cooling and noise reduction requirements during the test of rocket engines with different thrust.

[0007] Furthermore, the spray ring module includes a spray water ring, which is composed of multiple sets of stainless steel pipes spirally arranged and interconnected. Each pipe has a water inlet at its bottom and a support base fixed at its top. Several spray holes are provided on the inner side of the pipes that contact the gas. The water-cooled wall formed by the multiple spiral water rings ensures that the wellhead is not eroded by the high-temperature gas.

[0008] Furthermore, the support base includes a flange plate and supporting stiffeners, with the flange connected to a pre-embedded steel plate on the test stand floor via bolts. This structure provides stable support for the spray water ring, ensuring that it will not shift or loosen due to the impact and vibration of the combustion gases during rocket engine testing, thus guaranteeing the normal operation of the cooling system.

[0009] Furthermore, the angle between the spray nozzle and the horizontal plane is 10°~15°. This angle setting allows the cooling water to be sprayed into the gas in a more suitable direction, avoiding the cooling water being directly blown away by the gas, increasing the contact time and contact effect between the cooling water and the gas, thereby improving cooling efficiency and better protecting the wellhead from being burned by the high-temperature gas.

[0010] Furthermore, the core area spray structure includes a rectangular tube jacket composed of multiple rectangular tubes welded together with stainless steel gaskets. Multiple sets of spray holes are arranged on the air-facing surface of the rectangular tubes, and each rectangular tube has two sets of water inlet pipes and one set of drain pipes on both sides of its back. This design ensures rapid circulation of cooling water within the rectangular tubes, promptly removing heat transferred from the combustion gas. It also forms a gas-liquid mixture film flowing along the wall surface of the rectangular tubes, isolating the combustion gas and effectively reducing the combustion gas temperature and noise in the core area, protecting the core area of ​​the guide channel. Moreover, the structure has high strength and can withstand the impact of high-temperature, high-speed combustion gas.

[0011] Furthermore, the non-core area spray structure includes a main frame and cooling water pipes. The main frame is constructed from welded channel steel, and four sets of cooling water pipes are arranged in a "U" shape around the channel steel plate. Multiple sets of stainless steel duckbill nozzles are welded to the inside of the pipes. The main frame structure is robust and durable; the duckbill nozzles can produce a wide-angle fan-shaped spray with moderate impact, uniform liquid distribution, moderate droplet size, and strong anti-clogging ability.

[0012] Furthermore, the duckbill nozzles are arranged in a staggered pattern. This ensures maximum spray area, allowing cooling water to more evenly cover non-core areas and areas in contact with the gas, further improving thermal protection while reducing the risk of splashing and preventing unnecessary impact of cooling water on surrounding equipment.

[0013] Furthermore, protective skirts are provided on both sides of the main frame, and multiple sets of stiffening plates are designed on the back of the skirts. This can effectively improve the structural strength of the main frame, prevent the gas from scorching the surrounding walls, and at the same time provide better protection for the non-core area sprinkler structure.

[0014] Furthermore, the core area spray structure and the non-core area spray structure of the guide channel are connected by welding at their contact points, and multiple sets of stop blocks are provided on the back. This enhances the impact resistance of the core area structure of the guide channel, making the entire guide channel structure more stable. When subjected to high-temperature, high-speed gas impact, it can better maintain structural integrity, ensuring that the guide channel effectively guides the gas flow and plays a role in cooling and noise reduction.

[0015] Furthermore, it also includes a protective support module, located at the bottom of the test bench, welded to the guide channel via an adapter plate, forming a protective support structure made of channel steel and square tubing. This prevents wellhead cooling water from splashing onto the electrical equipment, avoiding damage due to moisture, thus ensuring the normal operation of the electrical equipment at the bottom of the test bench, extending equipment lifespan, and also providing an operating platform for post-test maintenance, facilitating equipment inspection and repair by personnel. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present invention; Figure 2 This is a schematic diagram of the main structure layout of an embodiment of the present invention; Figure 3 This is a schematic diagram of the spray ring module structure according to an embodiment of the present invention; Figure 4 This is a diagram showing the arrangement of spray holes on the spray water ring according to an embodiment of the present invention; Figure 5 for Figure 4 A cross-sectional view along the AA direction; Figure 6 This is a schematic diagram of the core area spray structure in an embodiment of the present invention; Figure 7 This is a schematic diagram of a rectangular tube structure according to an embodiment of the present invention; Figure 8 This is a diagram showing the arrangement of spray holes on a rectangular tube according to an embodiment of the present invention; Figure 9 This is a schematic diagram of the non-core area spray structure according to an embodiment of the present invention; Figure 10 This is a diagram showing the arrangement of the duckbill nozzles according to an embodiment of the present invention; Figure 11 This is a schematic diagram of the connection structure between the core area spray structure and the non-core area spray structure in an embodiment of the present invention; Figure 12 This is a schematic diagram of the protective bracket module structure according to an embodiment of the present invention; The attached diagram lists the components represented by each number as follows: 1. Spray ring module; 11. Spray water ring; 12. Inlet; 13. Flange plate; 14. Support rib plate; 15. Spray hole; 2. Guide channel module; 3. Test bench; 4. Test frame; 5. Support frame; 6. Guide channel; 7. Core area spray structure; 71. Rectangular tube jacket; 72. Inlet pipe; 73. Drain pipe; 8. Non-core area spray structure; 81. Main frame; 82. Cooling water pipe; 83. Duckbill nozzle; 84. Protective skirt plate; 85. Rib plate; 9. Stop block; 10. Protective bracket module; 101. Adapter plate. Detailed Implementation

[0017] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0018] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0019] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this technology based on the specific circumstances.

[0020] In the description of this application, spatial relation terms such as "below," "under," "below," "below," "above," "over," etc., are used herein to describe the relationship between one element or feature shown in the figures and other elements or features. It should be understood that, in addition to the orientation shown in the figures, spatial relation terms also include different orientations of the device in use and operation. For example, if the device in the figures is flipped, an element or feature described as "below" or "under" or "below" of other elements or features will be oriented "above" other elements or features. Therefore, the exemplary terms "below" and "under" can include both upper and lower orientations. Furthermore, the device may also include other orientations (e.g., rotated 90 degrees or other orientations), and the spatial descriptive terms used herein are interpreted accordingly.

[0021] In the description of this application, the term "for example" is used to mean "used as an example, illustration, or description." Any embodiment described as "for example" in this application is not necessarily to be construed as being more preferred or advantageous than other embodiments. The following description is provided to enable any person skilled in the art to make and use the invention. Details are set forth in the following description for purposes of explanation. It should be understood that those skilled in the art will recognize that the invention can be made without using these specific details. In other instances, well-known structures and processes will not be described in detail to avoid obscuring the description of the invention with unnecessary detail. Therefore, the invention is not intended to be limited to the embodiments shown, but is consistent with the broadest scope of the principles and features disclosed in this application.

[0022] like Figure 1As shown in Figure 12, this embodiment provides a rocket engine test stand spray cooling system, including a spray ring module 1 and a guide channel module 2. The spray ring module 1 is located at the wellhead of the test stand 3, coaxial with the center of the test frame 4, and includes a spray water ring 11, which is threadedly connected to a pre-embedded steel plate on the ground of the test stand 3. The guide channel module 2 is located at the bottom of the test stand 3, and includes a support frame 5 and a guide channel 6 (inclination angle not less than 45°) inclined on the top of the support frame 5. The support frame 5 is welded and fixed to the pre-embedded steel plate on the ground of the test stand 3. The guide channel 6 consists of a core area spray structure 7 and a non-core area spray structure 8 (the core spray area and non-core spray area of ​​the guide channel are determined according to the gas temperature distribution and the position of the maximum impact point obtained by simulation calculation). Both the spray ring module 1 and the guide channel module 2 are connected to an external water source through water pumps and valves. Specifically: The spray ring module 1 includes a spray water ring 11, which is composed of multiple sets of DN100 stainless steel pipes spirally arranged and interconnected. Each pipe has an inlet 12 at its bottom and a support base at its top. Several spray holes 15 are provided on the inner side of the pipes that contact the gas. Cooling water flows in from the bottom inlet pipe and flows upwards in the opposite direction. The cooling water flow rate can be controlled by a valve according to the gas flow rate. The water-cooled wall formed by the multiple spiral water rings ensures that the wellhead is not eroded by the high-temperature gas, and the spray water ring 11 provides a large cold source, effectively limiting the heat flow range and protecting other equipment.

[0023] In this embodiment, the support base includes a flange plate 13 and a support stiffener 14. The flange is connected to the pre-embedded steel plate on the test stand 3 via bolts. This structure provides stable support for the spray water ring 11, ensuring that the spray water ring 11 will not shift or loosen due to the impact and vibration of the combustion gases during rocket engine testing, thus guaranteeing the normal operation of the cooling system.

[0024] In this embodiment, the spray hole 15 has a diameter of 3mm, and the angle between the spray hole 15 and the horizontal plane is 10°~15°. This angle setting allows the cooling water to be sprayed into the gas in a more suitable direction, avoiding the cooling water being directly blown away by the gas, increasing the contact time and contact effect between the cooling water and the gas, thereby improving cooling efficiency and better protecting the wellhead from being burned by the high-temperature gas.

[0025] The core area spray structure 7 includes a rectangular tube jacket 71, composed of multiple rectangular tubes measuring 200*100*18 mm. The rectangular tubes are made of Q355B material and are welded together using stainless steel backing plates. Multiple sets of spray holes are provided on the air-facing (spraying) side of the rectangular tubes. Each rectangular tube has two sets of DN100 water inlet pipes 72 and one set of DN50 drain pipes 73 on both sides of its back. Cooling water enters the cavity through the two sets of DN100 water inlet pipes on the back of the rectangular tubes and is then sprayed out. Upon contact with the high-temperature combustion gas, it vaporizes, forming a gas-liquid mixture film flowing along the wall surface of the rectangular tube to isolate the combustion gas. The outer layer of water vapor mixes with the high-temperature combustion gas, reducing the combustion gas temperature and noise at the impact surface.

[0026] The non-core area spray structure 8 includes a main frame 81 and cooling water pipes 82. The main frame 81 is welded from channel steel with dimensions of 400×100×10.5 mm. Four sets of cooling water pipes 82 are arranged in a "U" shape around the channel steel plate, and multiple sets of stainless steel duckbill nozzles 83 are welded to the inside of the pipes. The main frame 81 is sturdy and durable, and the duckbill nozzles 83 can produce a wide-angle fan-shaped spray with moderate impact, uniform liquid distribution, moderate droplet size, and strong anti-clogging ability.

[0027] In this embodiment, the duckbill nozzles 83 are arranged in an alternating vertical configuration and slightly tilted downwards (the angle between the duckbill nozzles 83 and the pipe is 0-10°). This ensures maximum spray area, allowing cooling water to more evenly cover non-core areas and areas in contact with the gas, further improving thermal protection while reducing the risk of splashing and preventing unnecessary impact of cooling water on surrounding equipment.

[0028] In this embodiment, protective skirts 84 are provided on both sides of the main frame 81. The material is Q235B with a plate thickness of 20mm, and multiple sets of stiffening plates 85 are designed on the back of the skirts. This can effectively improve the structural strength of the main frame 81, ensure that the walls on both sides of the guide channel 6 are protected from the direct impact of high-temperature and high-speed gas, and at the same time provide better protection for the non-core area spray structure 8.

[0029] The core area spray structure 7 and the non-core area spray structure 8 of the flow guide channel 6 are connected by welding at their contact points, and multiple sets of stop blocks 9 are provided on the back. This enhances the impact resistance of the core area structure of the flow guide channel 6, making the entire flow guide channel 6 structure more stable. When subjected to the impact of high-temperature and high-speed gas, it can better maintain structural integrity, ensuring that the flow guide channel 6 effectively guides the gas flow and plays a role in cooling and noise reduction.

[0030] In this embodiment, a protective support module 10 is also included, located at the bottom of the test bench 3. It is welded to the guide channel 6 via an adapter plate 101, forming a protective support structure welded from channel steel with dimensions of 360×100×13mm and 6 sets of HW250*250 steel profiles. This protects the electrical equipment at the bottom of the test bench from wellhead cooling water inflow, preventing damage to the electrical equipment due to moisture, thereby ensuring the normal operation of the electrical equipment at the bottom of the test bench, extending the equipment's lifespan, and also providing an operating platform for post-test maintenance, facilitating equipment inspection and repair by personnel.

[0031] Compared to traditional methods for cooling and noise reduction on test stands, this invention features a thermal protection spray ring module at the wellhead of the test stand. This spray ring directly injects cooling water that interacts with the high-temperature combustion gas, reducing the internal temperature of the gas through gas-liquid phase change heat transfer, thus achieving cooling. The cooling range is large, protecting the wellhead foundation from ablation. An inclined guide channel is installed at the bottom of the test stand, with independent pipelines supplying water to both the core and non-core areas. The inclined guide channel utilizes its tilted structure to quickly and smoothly guide the high-temperature, high-speed combustion gas jets generated during rocket engine testing away from the test stand, preventing flames, smoke, and debris from reflecting back and impacting the test stand, damaging the engine and other supporting equipment. The independent pipeline water supply can accommodate water flow rates during tests of engines with different thrust levels. Furthermore, the cooling water in the spray system is pumped and the flow rate is controlled by valves, eliminating the need for a high-level water tank. This invention can meet the cooling and noise reduction requirements during the testing of rocket engines with different thrust levels.

[0032] While embodiments or examples of this disclosure have been described with reference to the accompanying drawings, it should be understood that the above embodiments are merely exemplary embodiments or examples, and the scope of the invention is not limited by these embodiments or examples, but only by the granted claims and their equivalents. Various elements in the embodiments or examples may be omitted or replaced by their equivalents. Furthermore, the steps may be performed in a different order than that described in this disclosure. Further, various elements in the embodiments or examples may be combined in various ways. Importantly, as the technology evolves, many elements described herein can be replaced by equivalents that appear after this disclosure.

Claims

1. A spray cooling system for a rocket engine test stand, characterized in that, Comprises a spray ring module and a diversion trench module; The spray ring module is arranged at the wellhead position of the test stand, coaxial with the center of the test frame, and comprises a spray water ring, which is in threaded connection with the embedded steel plate on the ground of the test stand; The diversion trench module is arranged at the bottom of the test stand, and comprises a support frame and a diversion trench obliquely arranged at the top of the support frame. The support frame is welded and fixed with the embedded steel plate on the ground of the test stand, and the diversion trench is composed of a core area spray structure and a non-core area spray structure; Wherein, the core area spray structure comprises a rectangular pipe jacket, which is composed of a plurality of rectangular pipes. Stainless steel backing plates are adopted for lap welding between the rectangular pipes. A plurality of groups of spray holes are arranged on the gas-facing surface of the rectangular pipes, and 2 groups of water inlet pipes and 1 group of drain pipes are arranged on both sides of the back of each rectangular pipe; Both the spray ring module and the diversion trench module are connected to an external water source through a water pump and a valve; 2. The rocket engine test stand spray cooling system according to claim 1, characterized in that, The spray water ring is spirally arranged by rolling of a plurality of groups of stainless steel pipes, the pipes are communicated with each other, a water inlet is arranged at the bottom of the pipes, a support seat is fixed at the top, and a plurality of spray holes are arranged on the inner side surface of the pipes in contact with fuel gas; 3. The rocket engine test stand spray cooling system according to claim 2, characterized in that, The support seat comprises a flange plate and a support rib plate, and the flange is connected with the embedded steel plate on the ground of the test stand through a screw rod; 4. The rocket engine test stand spray cooling system according to claim 2, characterized in that, The angle between the spray holes and the horizontal plane is 10°~15°; 5. The rocket engine test stand spray cooling system according to claim 1, characterized in that, The non-core area spray structure comprises a main body frame and cooling water pipes. The main body frame is formed by splicing and welding channel steels, 4 groups of cooling water pipes are arranged in a "square" shape around the channel steel plate, and a plurality of groups of stainless steel duckbill nozzles are welded on the inner side of the pipes; 6. The rocket engine test stand spray cooling system according to claim 5, characterized in that, The duckbill nozzles are arranged in a vertically staggered manner; 7. The rocket engine test stand spray cooling system according to claim 5, characterized in that, Protective skirt plates are arranged on both sides of the main body frame, and a plurality of groups of rib plates are designed on the back of the skirt plates; 8. The rocket engine test stand spray cooling system according to claim 1, characterized in that, The contact position between the core area spray structure and the non-core area spray structure of the diversion trench is connected by welding, and a plurality of groups of stop blocks are arranged on the back; 9. The rocket engine test stand spray cooling system according to claim 1, characterized in that, It also comprises a protective support module, which is arranged at the bottom of the test stand, welded with the diversion trench through an adapter plate, and is a protective support structure formed by splicing and welding channel steels and square pipes;

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