A receiving part for pulsating pressure test of an aero-engine and a packaging method thereof

Abstract

The application discloses a sensing part for aero-engine pulsating pressure test and a packaging method thereof, and belongs to the technical field of aero-engine pulsating pressure test; the method selects a pulsating pressure sensor based on environmental parameters of an installation measuring point, and performs initial technical parameter detection on the pulsating pressure sensor; the pulsating pressure sensor that meets the initial technical parameter detection standard is packaged into a sensor mounting seat; the sensor mounting seat is packaged with a sleeve through a connecting joint, and a cable of the pulsating pressure sensor is placed into the sleeve; the electric cable of the pulsating pressure sensor is welded to an aviation plug, and the aviation plug is connected with the sleeve, and the packaging of the sensing part is completed. The sensing part packaging process specification is optimized, the technical state of the sensing part after packaging is good, and the micro-motion and loosening of various components under the extreme vibration environment of the engine are effectively inhibited.

Description

Technical Field

[0001] This invention belongs to the field of aero-engine pulsation pressure testing technology, and relates to a sensing element for aero-engine pulsation pressure testing and its packaging method. Background Technology

[0002] In a pulsating pressure testing system, the sensing element is the core front-end unit that directly contacts the high-temperature, high-pressure gas and senses the pressure signal. Its performance directly determines the effectiveness of the entire testing system. A typical sensing element consists of a pulsating pressure sensor fixed inside a housing through a specific mechanical structure and packaging process. The core technology lies in two main aspects: first, accurately selecting a sensor with performance matching according to the operating conditions of the measurement point; and second, employing a stable and reliable packaging process to ensure that the sensor can transmit signals accurately and for a long time in extremely harsh environments.

[0003] However, the sensing element in existing technologies performs poorly and malfunctions frequently, severely hindering the normal progress of experimental work. For example... Figure 2 In the image, the left side shows the internal structure of the sensing element under normal conditions, while the right side shows the internal structure of the sensing element after the sensor has been removed. For example... Figure 3 The left side shows the air pressure distribution inside the sensing element under normal conditions, while the right side shows the air pressure distribution inside the sensing element after the sensor has been removed. First, there is a serious one-sidedness and limitation in sensor selection technology. Traditional selection methods often primarily consider the average pressure level at the measurement point. While this approach may be sufficient for steady-state or slowly varying pressure fields, it severely underestimates the extreme harshness of the dynamic environment inside aero-engines, especially at certain critical measurement points. Because the selection focuses solely on the single parameter of average pressure, completely ignoring dynamic environmental factors, the core sensitive components or packaging structure cannot withstand repeated peak impacts, thermal stress, and basic environmental loads, resulting in premature performance degradation or physical damage. This is one of the fundamental reasons for the extremely short lifespan of the sensing element. According to actual statistics, the average lifespan of the original sensing element is only about 20 days, with some lasting as little as one day. This high failure rate significantly increases testing costs and time. Second, the packaging process of the sensing element has defects, causing the sensor to frequently detach, leading to abnormal test data. Due to the unique nature of this type of engine pulsation testing system, once an abnormality is detected, troubleshooting requires stopping the engine and then diagnosing the pulsation system. Frequent malfunctions of the sensing element severely affect the normal operation of engine testing, reduce engine lifespan, and decrease the operational stability of the pulsation pressure testing system.

[0004] In summary, there is an urgent need to provide a new method for packaging the sensing element to reduce the failure frequency of the sensing element, extend the service life of the sensor, increase the structural stability of the sensing element, and ensure the operational stability of the pulsating pressure testing system during engine testing. Summary of the Invention

[0005] The purpose of this invention is to provide a sensing element for pulsating pressure testing of aero-engines and its packaging method, so as to solve the technical problem that the sensing element structure is unstable and prone to failure during the test process in the prior art.

[0006] To achieve the above objectives, the present invention employs the following technical solution: In a first aspect, the present invention provides a method for packaging a sensing element for testing the pulsating pressure of an aero-engine, comprising the following steps: The pulsating pressure sensor is selected based on the environmental parameters of the installation measurement point, and the initial technical parameters of the pulsating pressure sensor are detected. The pulsating pressure sensor that meets the initial technical parameter test standards is encapsulated in the sensor mounting base; The sensor mounting base is sealed to the sleeve via a connector, and the cable of the pulsating pressure sensor is placed inside the sleeve. Solder the electrical cable of the pulsating pressure sensor to the aviation connector, and connect the aviation connector to the sleeve to complete the encapsulation of the sensing part.

[0007] Furthermore, the environmental parameters of the installation measuring points include at least the average pressure, maximum pressure, temperature gradient, pressure gradient, ambient temperature, and ambient pressure.

[0008] Furthermore, the initial technical parameter testing includes at least electrical performance testing, sensitivity testing, and stability testing.

[0009] Furthermore, the step of encapsulating the pulsating pressure sensor, whose initial technical parameters have been tested and found to meet the standards, into the sensor mounting base specifically includes: An adhesive is applied to the surface of the pulsating pressure sensor, and the coated pulsating pressure sensor is then encapsulated in a sensor mounting base. The encapsulation is completed after the adhesive cures naturally.

[0010] Furthermore, the step of encapsulating the sensor mounting base with the sleeve via a connector and placing the cable of the pulsating pressure sensor into the sleeve specifically includes: Apply adhesive to the external threads of the sensor mounting base, screw the external threads of the mounting base into the connector, and allow the adhesive to cure naturally. Apply adhesive to the external thread of the connector, then connect and tighten the external thread of the connector to the sleeve, allowing the adhesive to cure naturally. Place the cable of the pulsating pressure sensor into the sleeve.

[0011] Furthermore, the adhesive is an epoxy resin adhesive or an organosilicone adhesive.

[0012] Furthermore, the aviation plug and the sleeve are connected by fasteners.

[0013] Furthermore, the fastener is a bolt.

[0014] Furthermore, the method also includes: Check whether the technical parameters of the packaged sensor are normal; if the inspection results are normal, put the sensing part into storage; if not, troubleshoot, repackage and inspect until the inspection results are normal.

[0015] Secondly, the present invention provides a sensing element for testing the pulsating pressure of an aero-engine, which is packaged according to the above-described method for packaging a sensing element for testing the pulsating pressure of an aero-engine.

[0016] Compared with the prior art, the present invention has the following beneficial effects: This invention discloses a sensing element and its packaging method for pulsating pressure testing of aero-engines. The method selects a sensor based on environmental parameters at the installation measurement point, considering various environmental factors to choose a suitable pulsating pressure sensor. It adds steps for applying and curing adhesive and detecting sensor technical parameters to ensure the sensing element is in good technical condition after packaging. This invention, through the organic combination of source selection optimization, process quality control, and end-performance verification, systematically solves the systemic defects of the original technology, ultimately achieving the comprehensive benefits of extended lifespan, improved stability, and reduced costs. After being put into use, the lifespan of the sensing element is extended to over 100 days, which is 5-10 times longer than before, and the stability of the pulsating pressure testing system is significantly improved; sensor losses are reduced from an average of 2000 yuan per day to 400 yuan, a reduction to 1 / 5 of the original cost. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a flowchart of the encapsulation method of the present invention; Figure 2 This is a schematic diagram of the internal structure of the sensing part according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the internal air pressure of the sensing part in an embodiment of the present invention.

[0019] Among them, 1-air intake tube; 2-sensor; 3-mounting base; 4-sleeve. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0021] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0022] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0023] In the description of the embodiments of the present invention, it should be noted that if terms such as "upper," "lower," "horizontal," or "inner" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is in use, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, terms such as "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0024] Furthermore, the use of the term "horizontal" does not imply that the component must be absolutely horizontal, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0025] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "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 the present invention according to the specific circumstances.

[0026] The present invention will now be described in further detail with reference to the accompanying drawings: See Figure 1 This invention discloses a method for packaging the sensing element for pulsating pressure testing of an aero-engine, comprising the following steps: S1, Select a pulsating pressure sensor based on the environmental parameters of the installation measurement point, and perform initial technical parameter detection on the pulsating pressure sensor; Analysis of engine pulsation pressure test data revealed that the average pressure change at this measuring point was not significantly different from other measuring points. However, the fluctuations were mainly caused by the following factors: 1) significant changes in maximum pressure under extreme conditions; 2) significant changes in temperature gradient; 3) significant changes in pressure gradient; 4) slightly higher ambient temperature; and 5) slightly higher ambient pressure. These factors occurred simultaneously or alternately, leading to significant fluctuations in the pulsation value at this measuring point, even exceeding limits. In the original sensor selection process, only average pressure was considered, neglecting other factors, resulting in a high frequency of sensor failures. Therefore, the environmental parameters for the installation measuring point in this invention should at least include average pressure, maximum pressure, temperature gradient, pressure gradient, ambient temperature, and ambient pressure.

[0027] The initial technical parameter testing includes at least electrical performance testing, sensitivity testing, and stability testing. This initial testing effectively filters out sensors with internal defects, substandard performance, or excessive zero-point drift. This prevents potentially defective components from entering the subsequent packaging process, saving material and labor costs.

[0028] S2, The pulse pressure sensor that has passed the initial technical parameter test is encapsulated in the sensor mounting base 3; The surface of the pulsating pressure sensor is coated with an adhesive, which is then encapsulated within the sensor mounting base 3. The adhesive cures naturally, completing the encapsulation process. The adhesive is either epoxy resin or silicone. This method differs from traditional methods that rely solely on mechanical clamping. The cured adhesive layer forms a strong chemical bond, fusing the sensor and mounting base 3 together, significantly enhancing the bonding strength and effectively resisting high-frequency vibrations and impacts generated during engine operation. This significantly reduces the risk of sensor failure due to loosening or fretting wear. In particular, the elastic silicone absorbs and buffers thermal stress caused by temperature cycling, reducing direct impact on the sensitive element and improving the long-term stability of the sensing part under environments with large temperature gradients.

[0029] S3, the sensor mounting base 3 is sealed to the sleeve 4 through the connecting connector, and the cable of the pulsating pressure sensor is put into the sleeve; S301, apply adhesive to the external thread of the sensor mounting base 3, screw the external thread of the mounting base 3 into the connector, and let the adhesive cure naturally. S302, apply adhesive to the external thread of the connector, connect and fasten the external thread of the connector to the sleeve 4, and allow the adhesive to cure naturally; S303, place the cable of the pulsating pressure sensor into the sleeve.

[0030] This embodiment utilizes a systematic application of fastening adhesive at critical mechanical connection points (threaded joints), a core innovation of this step. After curing, the adhesive fills the thread gaps, generating strong anti-loosening resistance, preventing relative rotation or loosening of the various connectors even under vibration. This ensures the integrity and rigidity of the entire sensing component's mechanical structure, solving the fatal problem of "sensors frequently falling off" in the original technology. Furthermore, placing the cable inside the sleeve 4 provides robust mechanical protection, preventing damage or accidental pulling in high-temperature, high-pressure airflow. Standardized cable management also avoids internal cable tangling or interference with components, improving product standardization and consistency.

[0031] S4. Solder the electrical cable of the pulsating pressure sensor to the aviation plug, and connect the aviation plug to the sleeve 4 to complete the encapsulation of the sensing part.

[0032] The aviation plug and sleeve 4 are connected by fasteners; the fasteners are preferably bolts, which provide vibration resistance and connection strength far exceeding that of simple threaded connections, ensuring the sealing and mechanical integrity of the final encapsulation end of the sensing part, and preventing this from becoming a weak point in the structure.

[0033] S5. Check whether the technical parameters of the packaged sensor are normal. If the inspection results are normal, put the sensing part into storage. If not, troubleshoot, repackage and inspect until the inspection results are normal.

[0034] This step can detect any negative impacts that may occur on sensor performance during the S2-S4 packaging process, ensuring that only sensors with completely normal technical parameters can be delivered for use, thereby improving the product's factory pass rate.

[0035] This invention discloses a sensing element for pulsating pressure testing of aero-engines, which is packaged according to the aforementioned packaging method for a sensing element used in pulsating pressure testing of aero-engines. The packaging process specifications of the sensing element are optimized to ensure that the packaged sensing element is in good technical condition, effectively suppressing the micro-movements and loosening of components under extreme engine vibration environments. During the intense vibrations generated when the engine is running at high speed, the components of the sensing element can be tightly connected and operate stably, without generating additional noise interference or signal distortion due to micro-movements, and without causing test interruption or data loss due to loosening. This allows the sensing element to maintain a high-precision and high-stability working state in the complex and ever-changing aero-engine environment, providing accurate and reliable data support for aero-engine pulsating pressure testing, and thus providing a strong basis for aero-engine performance evaluation, fault diagnosis, and optimized design.

[0036] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for encapsulating the sensing element for pulsating pressure testing of an aero-engine, characterized in that, Includes the following steps: A pulsating pressure sensor is selected based on the environmental parameters of the installation measurement point, and initial technical parameter testing is performed on the pulsating pressure sensor. The environmental parameters of the installation measurement point include at least the average pressure, maximum pressure, temperature gradient, pressure gradient, operating ambient temperature, and operating ambient pressure. The initial technical parameter testing includes at least electrical performance testing, sensitivity testing, and stability testing. The pulsating pressure sensor that meets the initial technical parameter test standards is encapsulated in the sensor mounting base; The sensor mounting base is sealed to the sleeve via a connector, and the cable of the pulsating pressure sensor is placed inside the sleeve; specifically including: Apply adhesive to the external threads of the sensor mounting base, screw the external threads of the mounting base into the connector, and allow the adhesive to cure naturally. Apply adhesive to the external thread of the connector, then connect and tighten the external thread of the connector to the sleeve, allowing the adhesive to cure naturally. Place the cable of the pulsating pressure sensor into the sleeve; Solder the electrical cable of the pulsating pressure sensor to the aviation connector, and connect the aviation connector to the sleeve to complete the encapsulation of the sensing part.

2. The method for encapsulating the sensing element for pulsating pressure testing of an aero-engine according to claim 1, characterized in that, The step of encapsulating the pulsating pressure sensor, whose initial technical parameters have been tested and found to meet the standards, into the sensor mounting base specifically includes: An adhesive is applied to the surface of the pulsating pressure sensor, and the coated pulsating pressure sensor is then encapsulated in a sensor mounting base. The encapsulation is completed after the adhesive cures naturally.

3. A method for encapsulating the sensing element for testing the pulsating pressure of an aero-engine according to claim 1 or 2, characterized in that, The adhesive is an epoxy resin adhesive or an organosilicone adhesive.

4. The method for encapsulating the sensing element for pulsating pressure testing of an aero-engine according to claim 1, characterized in that, The aviation plug and the sleeve are connected by fasteners.

5. The method for encapsulating the sensing element for pulsating pressure testing of an aero-engine according to claim 4, characterized in that, The fastener is a bolt.

6. The method for encapsulating the sensing element for pulsating pressure testing of an aero-engine according to claim 1, characterized in that, The method further includes: Check whether the technical parameters of the packaged sensor are normal; if the inspection results are normal, put the sensing part into storage; if not, troubleshoot, repackage and inspect until the inspection results are normal.

7. A sensing element for testing pulsating pressure in an aero-engine, characterized in that, The sensing element is packaged according to any one of claims 1 to 6 using a method for packaging the pulsating pressure test of an aero-engine.

Images