Dynamic simulation test system and method for high-altitude environment of centrifugal compressor

Abstract

The invention relates to a centrifugal compressor high-altitude environment dynamic simulation test system. The system comprises a compressor test module; the high-altitude environment simulation module comprises an air inlet surge tank, an air inlet assembly and a first air exhaust assembly which are arranged at the upstream of the air inlet pipeline, and an air exhaust surge tank and a second air exhaust assembly which are arranged at the downstream of the air exhaust pipeline; a measurement module; the control module is used for comparing the first actually-measured pressure value with a target altitude pressure value of the air inlet end and controlling the air inlet amount of the air inlet assembly and the air suction amount of the first air suction assembly according to a comparison result, so that the pressure of the air inlet pressure stabilizing tank is stabilized at the target altitude pressure of the air inlet end; and the control module compares the second actually measured pressure value with the target altitude pressure value of the exhaust end, and controls the air suction amount of the second air suction assembly according to the comparison result, so that the pressure of the exhaust surge tank is stabilized at the target altitude pressure value of the exhaust end. It is ensured that test data can truly reflect the actual plateau working condition performance of the gas compressor.

Description

Technical Field

[0001] This invention relates to the field of turbocharger testing technology, specifically to a dynamic simulation test system and method for centrifugal compressors in high-altitude environments. Background Technology

[0002] When a turbocharged engine calibrated on a plain is operated at high altitude, it will face many problems such as reduced engine power, incomplete combustion and turbocharger overspeed, and easy surge of centrifugal compressor. At the centrifugal compressor component level, it is necessary to carry out aerodynamic performance test research on centrifugal compressor under high altitude intake conditions to provide a basic test database for centrifugal compressor aerodynamic design.

[0003] In related technologies, centrifugal compressor test benches simulating high-altitude environments often focus on low intake pressure, resulting in incomplete simulations and significant deviations between the test results of key performance parameters such as compressor pressure ratio and surge point and actual high-altitude conditions. Summary of the Invention

[0004] In view of the above-mentioned defects or deficiencies in the prior art, the present invention proposes a dynamic simulation test system and method for centrifugal compressors in high-altitude environments.

[0005] This invention provides a dynamic simulation test system for a centrifugal compressor in a high-altitude environment, comprising: a compressor test module, including a centrifugal compressor, an intake pipe disposed upstream of the centrifugal compressor, and an exhaust pipe disposed downstream of the centrifugal compressor; a high-altitude environment simulation module, including an intake pressure stabilizing tank, an intake assembly, and a first extraction assembly disposed upstream of the intake pipe, and an exhaust pressure stabilizing tank and a second extraction assembly disposed downstream of the exhaust pipe, wherein the intake assembly and the first extraction assembly are respectively connected to the intake pressure stabilizing tank, and the second extraction assembly is connected to the exhaust pressure stabilizing tank; and a measurement module, including an intake pressure sensor and an exhaust pressure sensor, wherein the intake pressure sensor is adapted to detect a first measured pressure value of the intake pressure stabilizing tank, and the exhaust pressure sensor is adapted to detect... The control module is communicatively connected to the measuring module, the air intake component, the first air extraction component, and the second air extraction component. The control module compares the first measured pressure value with the target altitude pressure value at the air intake end to obtain a first comparison result. Based on the first comparison result, it controls the air intake volume of the air intake component and the air extraction volume of the first air extraction component, so that the pressure of the air intake pressure stabilizing tank is stable at the target altitude pressure at the air intake end. The control module also compares the second measured pressure value with the target altitude pressure value at the exhaust end to obtain a second comparison result. Based on the second comparison result, it controls the air extraction volume of the second air extraction component, so that the pressure of the exhaust pressure stabilizing tank is stable at the target altitude pressure value at the exhaust end.

[0006] In one optional embodiment, the centrifugal compressor high-altitude environment dynamic simulation test system further includes a heat exchanger, which is located on the intake pipe downstream of the intake pressure stabilizing tank. The heat exchanger is communicatively connected to the control module. The control module compares the temperature of the heat exchanger with the target intake temperature and adjusts the temperature of the heat exchanger according to the comparison result, so that the temperature of the heat exchanger is stabilized at the target intake temperature.

[0007] In one optional embodiment, the air intake assembly includes a fan and a pressure stabilizing chamber, the fan being connected to the air intake pressure stabilizing tank via an air intake pipe, and the pressure stabilizing chamber being located on the air intake pipe.

[0008] In one alternative embodiment, the air intake assembly further includes an air replenishment valve (22) disposed between the pressure stabilizing chamber (23) and the fan (21).

[0009] In one optional embodiment, the first suction assembly includes a first vacuum pump and a first suction regulating valve. The first vacuum pump is connected to the inlet pressure stabilizing tank via a first suction pipeline, and the first suction regulating valve is located on the first suction pipeline downstream of the inlet pressure stabilizing tank. The second suction assembly includes a second vacuum pump and a second suction regulating valve. The second vacuum pump is connected to the exhaust pressure stabilizing tank via a second suction pipeline, and the second suction regulating valve is located on the second suction pipeline downstream of the exhaust pressure stabilizing tank.

[0010] In one alternative embodiment, an exhaust cooler is provided downstream of the exhaust pipe, and the exhaust cooler is connected to a cold water tank.

[0011] In one optional embodiment, the compressor test module further includes an intake rectification system located at the downstream end of the intake pipe and upstream of the centrifugal compressor.

[0012] This invention also proposes a method for dynamic simulation testing of centrifugal compressors in high-altitude environments, comprising: setting a target altitude and determining the corresponding target altitude pressure value according to a standard atmospheric model; activating a high-altitude environment simulation module to evacuate air from the inlet pressure stabilizing tank and the exhaust pressure stabilizing tank to establish the low-pressure basic environment required by the system; acquiring a first measured pressure value detected by an inlet pressure sensor and a second measured pressure value detected by an exhaust pressure sensor; comparing the first measured pressure value and the second measured pressure value with the target altitude pressure value to obtain a first comparison result; and, based on the first comparison result, controlling the air intake of the inlet component to the inlet pressure stabilizing tank and the air extraction of the first extraction component to the inlet pressure stabilizing tank and the air extraction of the second extraction component to the exhaust pressure stabilizing tank to dynamically adjust the total airflow entering the system and balance the extraction volume, so that the pressure of the inlet pressure stabilizing tank and the exhaust pressure stabilizing tank is stabilized at the target altitude pressure value.

[0013] In one optional embodiment, the centrifugal compressor high-altitude environment dynamic simulation test method further includes: determining a target inlet temperature corresponding to the target altitude value; obtaining a heat exchanger temperature; comparing the heat exchanger temperature with the target inlet temperature to obtain a second comparison result; and adjusting the temperature of the heat exchanger according to the second comparison result so that the heat exchanger temperature is stable at the target inlet temperature.

[0014] The beneficial effects of this invention are as follows: By adjusting the intake volume of the intake assembly and the extraction volume of the first extraction assembly based on the first measured pressure value detected by the intake pressure sensor, the intake pressure stabilizing tank is kept at the target altitude pressure at the intake end; simultaneously, by adjusting the extraction volume of the second extraction assembly based on the second measured pressure value detected by the exhaust pressure sensor, the exhaust pressure stabilizing tank is kept at the target altitude pressure at the exhaust end. This achieves complete replication of intake pressure and exhaust back pressure in high-altitude environments, significantly reducing test deviations of key performance parameters such as compressor pressure ratio and surge point, ensuring that test data can truly reflect the actual high-altitude operating conditions of the compressor, and flexibly adapting to pressure simulation requirements at different altitudes, thus improving the reliability of test data and the applicability of the system. Attached Figure Description

[0015] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0016] Figure 1 This is a schematic diagram of the structure of a centrifugal compressor high-altitude environment dynamic simulation test system provided in an embodiment of the present invention;

[0017] Figure 2 This is a flowchart of a high-altitude dynamic simulation test method for a centrifugal compressor provided in an embodiment of the present invention.

[0018] Explanation of reference numerals in the attached drawings: 11-Inlet pipe; 12-Inlet rectifier system; 13-Centrifugal compressor; 14-Exhaust bypass valve; 15-Exhaust pipe; 21-Fan; 22-Make-up valve; 23-Pressure stabilizing chamber; 24-First vacuum pump; 25-First suction regulating valve; 26-Inlet pressure stabilizing tank; 27-Heat exchanger; 28-Second vacuum pump; 29-Second suction regulating valve; 210-Exhaust pressure stabilizing tank; 211-Exhaust cooler; 212-Cold water tank; 31-Flow meter; 32-Inlet parameter measurement system; 33-Speed ​​measurement system; 34-Speed ​​control system; 35-Drive system; 36-Outlet parameter measurement system; 37-Inlet pressure sensor; 38-Exhaust pressure sensor. Detailed Implementation

[0019] Existing technologies for simulating high-altitude environments in centrifugal compressor test benches often focus on low intake pressure, neglecting the impact of reduced intake temperature at high altitudes on engine performance and internal flow field.

[0020] Other approaches, while recognizing the importance of exhaust back pressure, simulate it by replacing turbines with different flow areas. This method is cumbersome, can only achieve static simulations at a few fixed altitude points, and cannot simulate continuous, dynamic altitude changes, thus limiting its flexibility in research and development testing.

[0021] Existing simulation devices can only simulate altitudes of a few thousand meters, while this solution can simulate the real environment at altitudes of tens of thousands of meters, and can simultaneously take into account environmental pressure and temperature to ensure the integrity of the simulated environment.

[0022] Therefore, there is an urgent need in this field for a component-level testing system and method that is cost-effective and can accurately, dynamically, and continuously simulate the high-altitude temperature and pressure environment at the compressor inlet and outlet.

[0023] The following is in conjunction with the appendix Figures 1 to 2 The present application will be further described in detail with reference to the embodiments. It is understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention. It should also be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0024] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments.

[0025] Please refer to Figure 1This invention provides a dynamic simulation test system for a centrifugal compressor in a high-altitude environment, comprising: a compressor test module, including a centrifugal compressor 13, an intake pipe 11 disposed upstream of the centrifugal compressor 13, and an exhaust pipe 15 disposed downstream of the centrifugal compressor 13; a high-altitude environment simulation module, including an intake pressure stabilizing tank 26, an intake assembly, and a first extraction assembly disposed upstream of the intake pipe 11, and an exhaust pressure stabilizing tank 210 and a second extraction assembly disposed downstream of the exhaust pipe 15, wherein the intake assembly and the first extraction assembly are respectively connected to the intake pressure stabilizing tank 26, and the second extraction assembly is connected to the exhaust pressure stabilizing tank 210; and a measurement module, including an intake pressure sensor 37 and an exhaust pressure sensor 38, wherein the intake pressure sensor 37 is adapted to detect the first exhaust pressure sensor 210 of the intake pressure stabilizing tank 26. A measured pressure value is obtained by an exhaust pressure sensor 38, which is suitable for detecting a second measured pressure value of the exhaust pressure stabilizing tank 210. A control module is communicatively connected to the measurement module, the intake component, the first extraction component, and the second extraction component. The control module compares the first measured pressure value with the target altitude pressure value at the intake end to obtain a first comparison result. Based on the first comparison result, the control module controls the intake volume of the intake component and the extraction volume of the first extraction component to stabilize the pressure of the intake pressure stabilizing tank 26 at the target altitude pressure at the intake end. The control module also compares the second measured pressure value with the target altitude pressure value at the exhaust end to obtain a second comparison result. Based on the second comparison result, the control module controls the extraction volume of the second extraction component to stabilize the pressure of the exhaust pressure stabilizing tank 210 at the target altitude pressure value at the exhaust end.

[0026] In this embodiment, the centrifugal compressor high-altitude environment dynamic simulation test system mainly includes a compressor test module, a high-altitude environment simulation module, a measurement module, and a control module.

[0027] The compressor test module is the core execution unit of the simulation test. The centrifugal compressor 13 is equipped with a speed measurement system 33, a speed regulation system 34 and a drive system 35 connected to the centrifugal compressor 14, as well as a compressor outlet parameter measurement system 36 located downstream of the centrifugal compressor 13.

[0028] The speed control system 34 and drive system 35 can simulate the speed output under actual working conditions, while the speed measurement system 33 provides real-time feedback of the compressor speed, ensuring that the speed parameters are controllable and measurable during the test.

[0029] The high-altitude environment simulation module can replicate the high-altitude environment.

[0030] The air intake assembly is used to control the access of the external high-pressure air source and regulate the air intake flow; the first air extraction assembly can achieve high-vacuum air extraction.

[0031] The vacuum level and pumping rate of the second pumping component can be adjusted according to the target altitude pressure requirements, and the pumping volume at the exhaust end can be adjusted in real time to ensure the pressure of the exhaust pressure stabilizing tank 210 is stable.

[0032] The control module employs a control architecture combining a PLC (Programmable Logic Controller) and an industrial computer, offering high reliability and strong scalability. It incorporates a built-in high-altitude environmental pressure-altitude database, allowing for preset target pressure values ​​at different altitudes (e.g., 5000m, 10000m, 15000m) according to experimental requirements. At the data acquisition level, a data acquisition card receives pressure and other parameters transmitted from the measurement module in real time, with a sampling frequency exceeding 100Hz, ensuring real-time and continuous data acquisition. At the control logic level, a PID (Proportional-Integral-Derivative) closed-loop control algorithm is used. The first measured pressure value is compared with the target altitude pressure value at the inlet, the pressure deviation is calculated, and the inlet assembly and the first extraction assembly are automatically adjusted to achieve dynamic pressure balance in the inlet pressure tank 26. Similarly, by comparing the second measured pressure value with the target altitude pressure value at the exhaust end, the second extraction assembly is adjusted to stabilize the pressure in the exhaust pressure tank 210.

[0033] In addition, the control module can be equipped with a visual operation interface, which can display the test parameter curves and equipment operating status in real time, and support the storage, export and playback of test data, which facilitates subsequent test analysis and report generation.

[0034] The system, through the coordinated action of the intake component, the first extraction component, and the second extraction component, can accurately simulate pressure environment parameters at different altitudes. It also employs a PID closed-loop control algorithm to adjust the intake and extraction volumes in real time, ensuring that the pressure in the intake and exhaust pressure tanks remains stable at the target altitude pressure value (pressure control accuracy can reach ±0.5 kPa). This effectively replicates actual high-altitude working conditions, providing a realistic and reliable environmental basis for centrifugal compressor performance testing and ensuring that the test data accurately reflects the compressor's working status in high-altitude environments.

[0035] The control module compares the first measured pressure value of the intake pressure stabilizing tank with the target altitude pressure value at the intake end, and synchronously adjusts the intake volume of the intake component and the extraction volume of the first extraction component to form a two-way dynamic balance adjustment mechanism. This mechanism can quickly offset pressure fluctuations and ensure that the pressure of the intake pressure stabilizing tank is stable at the target value. It provides the centrifugal compressor with an intake pressure environment consistent with the actual altitude, and avoids the compressor performance test results being affected by intake pressure deviations.

[0036] The system is designed with pressure control logic for the exhaust pressure stabilizing tank. The control module precisely adjusts the pumping volume of the second extraction component based on the difference between the second measured pressure value and the target altitude pressure value at the exhaust end. This stabilizes the exhaust pressure and can realistically simulate the exhaust back pressure environment of the compressor at different altitudes, ensuring that the compressor inlet and outlet pressures meet the high-altitude operating conditions and fully reflect its actual working status in the high-altitude environment.

[0037] The control module communicates in real time with the measurement module and execution components (intake and extraction components), enabling rapid acquisition of pressure data and output of adjustment commands. This shortens the correction time for pressure deviations and prevents pressure fluctuations from continuously affecting the experiment. This high-efficiency response characteristic meets the dynamic simulation requirements for rapid pressure switching at different altitudes in high-altitude environments, improving experimental efficiency and flexibility.

[0038] By precisely controlling the pressure at the inlet and outlet ends, the system can stably reproduce core pressure parameters at different altitudes, eliminating experimental errors caused by unstable environmental pressure. The centrifugal compressor performance data (such as pressure ratio and efficiency) measured under this stable environment more closely reflects actual high-altitude operating conditions, providing reliable data support for compressor design optimization and performance verification.

[0039] Furthermore, the centrifugal compressor high-altitude environment dynamic simulation test system also includes a heat exchanger 27, which is located on the intake pipe 11 downstream of the intake pressure stabilizing tank 26. The heat exchanger 27 is connected to the control module. The control module compares the temperature of the heat exchanger 27 with the target intake temperature and adjusts the temperature of the heat exchanger according to the comparison result so that the temperature of the heat exchanger is stabilized at the target intake temperature.

[0040] Inlet air temperature is a key parameter affecting the aerodynamic performance of centrifugal compressors (such as flow rate, pressure ratio, and efficiency). Stabilizing the inlet air temperature in the heat exchanger can avoid deviations in test data caused by fluctuations in inlet air temperature, ensuring that the measured compressor performance data (such as compression efficiency and outlet pressure) can truly reflect its actual performance under high-altitude temperature and pressure conditions, thus improving the reliability of test results.

[0041] By adding a heat exchanger 27 linked to the control module in the intake duct, the intake air temperature can be adjusted in a targeted manner. The control module compares the actual temperature of the heat exchanger with the target intake air temperature and makes dynamic corrections, which can accurately reproduce the intake air temperature conditions at different altitudes (such as low temperature at high altitude and normal temperature at low altitude), solve the problem that pressure control alone cannot simulate the temperature and pressure coordination environment at high altitudes, and make the intake air parameters more consistent with real high-altitude conditions.

[0042] The control module allows for flexible adjustment of the heat exchanger, enabling rapid switching between different target inlet air temperatures (e.g., switching from -50℃ high-altitude low temperature to 20℃ low-altitude normal temperature). It can simulate high-altitude and multi-temperature combinations without additional equipment modifications, meeting the performance verification needs of centrifugal compressors under different temperature and pressure environments and significantly expanding the system's applicability.

[0043] The system adds closed-loop temperature control to the precise pressure control, ensuring stable pressure and temperature parameters at the intake end. A stable intake temperature and pressure environment avoids compressor surge and efficiency fluctuations caused by sudden changes in intake parameters, ensuring smoother compressor operation during testing and reducing the risk of equipment failure due to unstable operating conditions.

[0044] Furthermore, the air intake assembly includes a fan 21 and a pressure stabilizing chamber 23. The fan 21 is connected to the air intake pressure stabilizing tank 26 through the air intake pipeline, and the pressure stabilizing chamber 23 is located on the air intake pipeline.

[0045] The pressure stabilizing chamber 23 is located downstream of the fan 21. The fan 21 is prone to airflow pulsation during operation, leading to pressure fluctuations in the airflow entering the intake pressure stabilizing tank. Unstable, pulsating airflow entering the centrifugal compressor may disrupt its internal flow field, causing decreased compressor efficiency, abnormal operating noise, or even surge. By placing the pressure stabilizing chamber 23 downstream of the fan, the internal space can buffer airflow impacts and balance pressure fluctuations, allowing the airflow to enter the subsequent intake pressure stabilizing tank 26 in a more stable state. The stabilizing effect of the pressure stabilizing chamber 23 reduces airflow disturbances entering the compressor, ensuring the compressor operates under more stable intake conditions, protecting the equipment and preventing airflow disturbances from affecting the accuracy of test data.

[0046] The pressure stabilizing chamber 23 can pre-balance the pressure fluctuations of the airflow output by the fan, thereby reducing the magnitude of pressure changes in the airflow entering the intake pressure stabilizing tank 26. This reduces the frequency and magnitude of the control module's adjustment of the intake volume of the intake component and the extraction volume of the first extraction component, reducing system adjustment losses and improving overall control efficiency and stability.

[0047] The flow stabilization function of the pressure stabilizing chamber 23 ensures a more consistent initial airflow state (pressure and velocity stability) for each test, avoiding fluctuations in initial test conditions caused by differences in fan airflow pulsation. Based on a consistent airflow foundation, the compressor performance data measured in multiple tests exhibits higher repeatability, facilitating comparative analysis and verification of test results.

[0048] Furthermore, the air intake assembly also includes an air replenishment valve 22, which is located between the pressure stabilizing chamber 23 and the fan 21.

[0049] The air replenishment valve 22 is located downstream of the blower 21 and upstream of the pressure stabilizing chamber 23. It can be flexibly opened to replenish air when the blower 21 supplyes insufficient air (such as when a larger air intake compensation is required for high-altitude high-vacuum simulation), quickly supplementing the air intake pipeline flow. In conjunction with the control module to regulate the air intake volume, it can more efficiently adapt to the air intake flow requirements under different altitude target pressures, avoid pressure fluctuations in the air intake pressure stabilizing tank due to insufficient flow, and improve the pressure regulation response speed.

[0050] The gas is first initially supplied by the fan 21, then the flow rate is precisely fine-tuned by the air supply valve 22, and finally enters the pressure stabilizing chamber 23 to buffer pulsations. This process ensures that the airflow entering the pressure stabilizing chamber 23 reaches a stable state first, reducing pressure fluctuations within the chamber caused by sudden changes in flow rate. This allows the pressure stabilizing chamber 23 to focus more on weakening airflow pulsations, further improving the stability of the airflow in the subsequent air intake pipe and air intake pressure stabilizing tank 26.

[0051] By setting up the air supply valve 22, it is no longer necessary to frequently adjust the fan speed to meet the flow requirements of different operating conditions—when the flow requirement is low, the fan alone supplies air, and when the flow requirement is high, the air supply valve 22 provides supplementary air. Therefore, the frequency of fan start-up and shutdown and speed fluctuations are reduced, the mechanical wear of the fan is reduced, its service life is extended, and the additional energy consumption caused by high-frequency fan adjustment is avoided.

[0052] In addition, if the fan 21 experiences a brief air supply shortage (such as a sudden increase in load), the air replenishment valve 22 can quickly respond to replenish air, avoiding test interruption caused by a sudden drop in the air intake pipeline flow. This design provides a flow compensation backup for the air intake system, enhances the reliability of system operation, and ensures the continuous and stable conduct of high-altitude environment simulation tests.

[0053] Furthermore, the first suction assembly includes a first vacuum pump 24 and a first suction regulating valve 25. The first vacuum pump 24 is connected to the inlet pressure stabilizing tank 26 through a first suction pipeline, and the first suction regulating valve 25 is located on the first suction pipeline downstream of the inlet pressure stabilizing tank 26. The second suction assembly includes a second vacuum pump 28 and a second suction regulating valve 29. The second vacuum pump 28 is connected to the exhaust pressure stabilizing tank 210 through a second suction pipeline, and the second suction regulating valve 29 is located on the second suction pipeline downstream of the exhaust pressure stabilizing tank 210.

[0054] In this embodiment, both the first and second pumping components adopt a combination design of "vacuum pump + pumping regulating valve". The vacuum pump provides a stable pumping foundation, while the pumping regulating valves (located near the inlet and outlet pressure tanks respectively) can finely adjust the pumping volume under the command of the control module. This "coarse adjustment + fine adjustment" mode can quickly respond to pressure deviations and stabilize the pressure of the inlet and outlet pressure tanks at the target altitude pressure value (such as a control accuracy of ±0.3 kPa), solving the problem that a single vacuum pump is difficult to achieve micro-pumping adjustment.

[0055] The control module can adjust the suction parameters of the two suction components according to the different target pressure requirements of the intake and exhaust ends (such as lower intake pressure and slightly higher exhaust pressure at high altitudes). This can realistically reproduce the difference in intake and exhaust pressure at different altitudes and avoid the limitation that a single suction component cannot meet the pressure requirements at both ends.

[0056] The suction regulating valve can dynamically adjust its opening according to the actual pressure deviation, eliminating the need for frequent start-stop or full-load operation of the vacuum pump. When the pressure in the pressure tank approaches the target value, simply reducing the valve opening can maintain the pressure, thus reducing load fluctuations and mechanical wear on the vacuum pump. Simultaneously, the suction assembly avoids the risk of overloading a single vacuum pump, significantly extending the equipment's service life.

[0057] If a minor malfunction occurs in one of the pumping components (such as a decrease in the pumping force of a single vacuum pump), the control module can compensate by increasing the opening of the corresponding pumping regulating valve or optimizing the parameters of another component, thus preventing the test from being interrupted due to a problem with a single component. In addition, the regulating valve near the pressure stabilizing tank can quickly cut off the pumping passage to prevent a sudden drop in pressure in the pressure stabilizing tank, further ensuring the stability and safety of the test process.

[0058] Furthermore, an exhaust cooler 211 is provided downstream of the exhaust pipe 15, and the exhaust cooler 211 is connected to a cold water tank 212.

[0059] The centrifugal compressor exhaust temperature is high, and the high-temperature airflow can easily cause the gas inside the exhaust pressure stabilizing tank 210 to expand, resulting in pressure fluctuations. The exhaust cooler 211 can quickly cool down the exhaust by using the cold water tank 212, keeping the exhaust temperature within a stable range, avoiding interference from temperature changes on the exhaust pressure, helping to maintain the pressure in the exhaust pressure stabilizing tank consistent with the target altitude pressure, and improving the accuracy of exhaust environment simulation.

[0060] High-temperature exhaust gas accelerates the aging of secondary extraction components (such as the secondary vacuum pump and secondary extraction regulating valve), damages seals, and reduces equipment reliability. Exhaust gas coolers can reduce high-temperature exhaust gas to a safe temperature range, preventing downstream extraction equipment from malfunctioning due to prolonged high-temperature operation, significantly extending the service life of the secondary extraction components and related exhaust pipe parts, and reducing equipment maintenance costs.

[0061] Exhaust temperature is a crucial parameter for analyzing compressor thermodynamic performance (such as adiabatic efficiency and heat loss). High temperatures can also affect the measurement accuracy of exhaust pressure sensors. After the exhaust cooler 211 stabilizes the exhaust temperature, it provides a suitable working environment for the exhaust pressure sensor, ensuring accurate pressure measurements. Furthermore, it allows the measured exhaust temperature and pressure data to better reflect actual high-altitude operating conditions, providing more reliable parameters for compressor performance evaluation.

[0062] Directly venting high-temperature exhaust gas can raise the ambient temperature at the test site, posing a risk of burns to personnel and potentially affecting the normal operation of surrounding equipment. The exhaust gas cooler 211 achieves efficient cooling through a cold water tank, reducing the exhaust gas temperature to a safe range. This improves the working environment at the test site, avoids safety hazards caused by high-temperature gas, and enhances the safety of the testing process.

[0063] Furthermore, the compressor test module also includes an intake rectification system 12, which is located at the downstream end of the intake duct 11 and upstream of the centrifugal compressor 13. The intake rectification system 12 can eliminate eddies and disturbances in the intake airflow, ensuring that the airflow enters the centrifugal compressor 13 in a uniform and stable state, and avoiding airflow turbulence from affecting the compressor's working efficiency and the accuracy of test data.

[0064] In another embodiment, the compressor test module includes a centrifugal compressor 13 and an intake pipe 11 and an intake rectifier system 12 located upstream of the centrifugal compressor 13 for transmitting and stabilizing airflow, and an exhaust bypass valve 14 and an exhaust pipe 15 located downstream of the centrifugal compressor 13 for regulating compressor flow and guiding exhaust. The operating point of the compressor is changed by adjusting the opening of the exhaust bypass valve 14.

[0065] The high-altitude environment simulation module is used to establish and maintain the high-altitude low-pressure environment required for the inlet and outlet of the centrifugal compressor 13. The module includes an inlet pressure stabilizing tank 26 located upstream of the inlet pipe 11, a fan 21, a make-up air valve 22, and a pressure stabilizing chamber 23 located upstream of the inlet pressure stabilizing tank 26, and an exhaust pressure stabilizing tank 210 located downstream of the exhaust pipe 15. A first vacuum pump 24 and a first extraction regulating valve 25 are connected to the inlet pressure stabilizing tank 26, and a second vacuum pump 28 and a second extraction regulating valve 29 are connected to the exhaust pressure stabilizing tank 210. These two valves can simultaneously extract air from the system to establish and maintain the same low-pressure environment at the compressor inlet and outlet. A make-up air valve 22 connects the inlet and exhaust sides of the pipeline for fine-tuning the system pressure balance. An exhaust cooler 211 and a connected cold water tank 212 are also installed between the exhaust pipe 15 and the exhaust pressure stabilizing tank 210 to cool the high-temperature gas discharged from the compressor while maintaining low back pressure, thus protecting downstream equipment.

[0066] The measurement module includes a flow meter 31 installed in the intake pipe 12 for measuring the intake flow rate; a centrifugal compressor inlet parameter measurement system 32 installed upstream of the centrifugal compressor 14 and a compressor outlet parameter measurement system 36 installed downstream of the centrifugal compressor 14 for collecting compressor performance parameters; a speed measurement system 33, a speed regulation system 34, and a drive system 35 connected to the centrifugal compressor 14 for driving and controlling the compressor speed; and a pressure sensor 37 installed on the wall of the intake pressure stabilizing tank and a pressure sensor 38 installed on the wall of the exhaust pressure stabilizing tank for real-time monitoring of the tank pressure.

[0067] The measurement module is used to: receive the actual pressure value measured by pressure sensors 37 and 38, compare the actual pressure value with the preset target altitude pressure value, and dynamically adjust the total air flow into the system by controlling the opening of the air supply valve 22, the first air extraction regulating valve 25 and the second air extraction regulating valve 29 through closed-loop control to balance the air extraction volume, thereby accurately stabilizing the pressure in the pressure tank at the target altitude pressure value.

[0068] The system's exhaust port is connected to both the intake pressure tank 26 and the exhaust pressure tank 210 via pipelines to simultaneously establish and maintain the same low-pressure environment at the compressor inlet and outlet. Between the outlet of the centrifugal compressor 13 and the exhaust pressure tank 210, a high-flow-capacity exhaust cooler 211 is installed to cool the gas before it enters the compressor test module while maintaining a low exhaust back pressure. A first exhaust regulating valve 23 is installed between the intake pressure tank 26 and the first vacuum pump 24 to jointly control the pressure with the first vacuum pump 24. A second exhaust regulating valve 29 is installed between the exhaust pressure tank 210 and the second vacuum pump 28 to jointly control the pressure with the second vacuum pump 28. A heat exchanger 27 is installed between the intake pressure tank 26 and the intake pipe 11 to simulate the intake temperature at the target altitude.

[0069] This experimental system dynamically simulates a high-altitude, low-pressure environment using the principle of "vacuum-replenishment." Its core function is to extract gas using a vacuum pump system to reduce system pressure, while simultaneously replenishing an appropriate amount of air by adjusting valves. This allows the system to achieve flow balance during the dynamic process, thereby stabilizing the pressure at the target value.

[0070] like Figure 2 As shown, this invention also proposes a method for dynamic simulation testing of centrifugal compressors in high-altitude environments, comprising the following steps:

[0071] Step S101: Set the target altitude and determine the corresponding target altitude pressure value according to the standard atmospheric model.

[0072] Step S103: Start the high-altitude environment simulation module to extract air from the intake pressure tank 26 and the exhaust pressure tank 210 respectively to establish the low-pressure basic environment required by the system.

[0073] Step S105: Obtain the first measured pressure value detected by the intake pressure sensor 37 and the second measured pressure value detected by the exhaust pressure sensor 38;

[0074] Step S107: Compare the first measured pressure value and the second measured pressure value with the target altitude pressure value respectively to obtain the first comparison result;

[0075] Step S109: Based on the first comparison result, control the air intake of the air intake assembly to the air intake pressure stabilizing tank 26 and the air extraction of the first air extraction assembly to the air intake pressure stabilizing tank 26 and the air extraction of the second air extraction assembly to the exhaust pressure stabilizing tank 210, so as to dynamically adjust the total air flow entering the system, balance the air extraction volume, and stabilize the pressure of the air intake pressure stabilizing tank 26 and the exhaust pressure stabilizing tank 210 at the target altitude pressure value.

[0076] The experimental method is based on a standard atmospheric model and determines the corresponding target altitude pressure value according to the set target altitude, rather than subjectively setting pressure parameters. This can accurately match the real atmospheric pressure characteristics at different altitudes, providing a scientific and reliable pressure benchmark for subsequent environmental simulations and ensuring the authenticity of the high-altitude environment replication from the source.

[0077] First, the high-altitude environment simulation module is activated in step S103 to evacuate air from the inlet and outlet pressure stabilizing tanks, establishing a low-pressure basic environment, before proceeding to the subsequent pressure fine-tuning stage. This step-by-step operation avoids the sudden pressure change that occurs when the system directly switches from atmospheric pressure to the target low pressure, reducing the impact on the inlet components, evacuation components, and compressor, ensuring a smooth equipment startup process, and reducing the risk of startup failure.

[0078] By acquiring the measured pressure value in real time and comparing it with the target value, the intake and extraction volumes are dynamically adjusted to form a closed-loop control logic of "measurement-comparison-adjustment". This dynamic balancing method can quickly offset pressure fluctuations in the intake and exhaust pressure tanks (such as pressure rises or falls caused by airflow disturbances), ensuring that the pressure at both ends is stable at the target altitude pressure value, and avoiding the problem that static adjustment cannot cope with pressure changes.

[0079] The test method clearly defines a standardized process of "setting parameters - establishing a basic environment - detecting pressure - comparative adjustment," with each step having a clear objective and execution logic. This standardized process avoids inconsistencies in test conditions caused by human error, ensuring the comparability and repeatability of test data from different batches and operated by different personnel, thus providing reliable data support for the performance analysis and verification of centrifugal compressors.

[0080] Furthermore, the dynamic simulation test method for centrifugal compressors in high-altitude environments also includes the following steps:

[0081] Step S201: Determine the target intake temperature corresponding to the target altitude value.

[0082] Step S203: Obtain the heat exchanger temperature.

[0083] Step S205: Compare the heat exchanger temperature with the target inlet air temperature to obtain a second comparison result.

[0084] Step S207: Adjust the temperature of the heat exchanger according to the second comparison result so that the temperature of the heat exchanger is stable at the target inlet temperature.

[0085] The experimental method introduces a new temperature control step. First, the target inlet air temperature is determined based on the target altitude. Then, a closed-loop logic of "temperature measurement-price comparison-temperature adjustment" is used to stabilize the heat exchanger temperature, ensuring that the inlet air simultaneously meets the target pressure and temperature parameters. This design solves the problem that pressure control alone cannot reproduce the high-altitude temperature-pressure coupling characteristics, making the simulated environment more closely resemble real high-altitude atmospheric conditions.

[0086] Inlet air temperature directly affects the aerodynamic performance of centrifugal compressors (such as flow rate, pressure ratio, and adiabatic efficiency). By precisely controlling the heat exchanger temperature, deviations in test data caused by fluctuations in inlet air temperature can be avoided, ensuring that the measured compressor performance parameters (such as compression efficiency and outlet temperature) accurately reflect its actual performance under high-altitude temperature and pressure conditions, thus improving the reliability of test results.

[0087] This temperature control procedure supports flexible matching of target inlet temperatures based on different target altitudes (e.g., normal temperature at low altitudes, low temperature at high altitudes), simulating high-altitude operating conditions with multiple altitude and temperature combinations without adjusting the core test process. It can meet the performance verification needs of centrifugal compressors under different temperature and pressure environments, significantly expanding the applicable scenarios of the test method.

[0088] The newly added steps clarify the standardized operating logic of "determining the target temperature - detecting the actual temperature - comparing and adjusting," avoiding inconsistencies in test conditions caused by human differences in temperature control. Based on a unified temperature and pressure control standard, the initial air intake state of different batches of tests is more stable, the test data repeatability is higher, and it is easier to compare, analyze, and optimize the compressor performance.

[0089] In this embodiment, the target altitude is first set, and the corresponding target environmental pressure and target intake temperature are determined according to the standard atmospheric model.

[0090] Start the high-altitude environment simulation module, turn on the intake vacuum pump 24 and the exhaust vacuum pump 28 to evacuate the intake pressure stabilizing tank 26 and the exhaust pressure stabilizing tank 210 respectively, and quickly establish the low-pressure basic environment required by the system.

[0091] During the air extraction process, the measurement and control system 3 monitors the actual pressure in the intake pressure stabilizing tank 26 and the exhaust pressure stabilizing tank 210 in real time through pressure sensors 37 and 38.

[0092] The control system compares the monitored actual pressure with the preset target environmental pressure. Based on the difference, it continuously adjusts the opening of the intake regulating valve 25, exhaust regulating valve 29, and make-up air valve 22 using closed-loop control algorithms such as PID control. This ensures that the total airflow entering the system, including the working flow and make-up flow of the centrifugal compressor 13, is balanced with the gas flow extracted by the vacuum systems 24 and 28, thereby accurately and stably maintaining the pressure in the intake and exhaust pressure tanks near the target environmental pressure. Simultaneously, the control heat exchanger 27 regulates and stabilizes the intake air temperature at the target intake air temperature.

[0093] Once the system's inlet and outlet pressures and inlet temperature stabilize at the target values, the drive system 35 is started, and the centrifugal compressor 13 is driven to the target speed via the speed control system 34. The compressor's operating point is changed by adjusting the opening of the exhaust bypass valve 14. Aerodynamic characteristic parameters under different operating conditions are collected by the flow meter 31, inlet parameter measurement system 32, outlet parameter measurement system 36, and speed measurement system 33 to complete the performance test in a high-altitude environment.

[0094] The centrifugal compressor high-altitude environment dynamic simulation test system of this invention, by constructing an inlet and outlet dual pressure stabilizing tank and a vacuum suction system, and in conjunction with a high-precision measurement and control system, can accurately, stably and dynamically simulate the inlet and outlet low-pressure environment and inlet air temperature of a centrifugal compressor at different altitudes. It provides a reliable test platform for obtaining the real aerodynamic performance of the compressor in a high-altitude environment, with high test simulation accuracy and fast control response.

[0095] The present invention has achieved the following beneficial technical effects:

[0096] 1. By using an intake pressure stabilizing tank, an exhaust pressure stabilizing tank, and a vacuum system, the intake and exhaust environments at high altitude and low pressure are simulated simultaneously, taking into account both ambient temperature and pressure, making the results closer to reality.

[0097] 2. The simulation is dynamic and continuously adjustable. Unlike static simulation methods that involve replacing parts, this invention uses a closed-loop control of the intake regulating valve to conveniently, quickly, and continuously simulate any altitude from the ground to tens of thousands of meters above the ground. It can even simulate the process of a plane rapidly climbing or descending.

[0098] 3. It ensures the stability and accuracy of the simulated pressure, and effectively suppresses airflow pulsation through the monitoring of the pressure stabilizing tank sensor.

[0099] 4. Compared to large high-altitude environmental chambers, this invention focuses on component-level testing, resulting in higher control precision.

[0100] 5. This invention not only simulates a complete and dynamically adjustable environment, but also provides precise control, system stability, system simplicity, controllable cost, and a more streamlined system structure, resulting in lower implementation costs.

[0101] The above description is merely a preferred embodiment of this application and an explanation of the technical principles employed. Those skilled in the art should understand that the scope of the invention involved in this application is not limited to technical solutions formed by specific combinations of the above-described technical features, but should also cover other technical solutions formed by arbitrary combinations of the above-described technical features or their equivalents without departing from the inventive concept. For example, technical solutions formed by substituting the above features with (but not limited to) technical features with similar functions disclosed in this application.

Claims

1. A dynamic simulation test system for a centrifugal compressor in a high-altitude environment, characterized in that, include: The compressor test module includes a centrifugal compressor (13), an intake pipe (11) located upstream of the centrifugal compressor (13), and an exhaust pipe (15) located downstream of the centrifugal compressor (13). The high-altitude environment simulation module includes an intake pressure stabilizing tank (26) and an intake assembly, a first extraction assembly, and an exhaust pressure stabilizing tank (210) and a second extraction assembly, which are located upstream of the intake pipe (11). The intake assembly and the first extraction assembly are respectively connected to the intake pressure stabilizing tank (26), and the second extraction assembly is connected to the exhaust pressure stabilizing tank (210). The measurement module includes an intake pressure sensor (37) and an exhaust pressure sensor (38). The intake pressure sensor (37) is adapted to detect a first measured pressure value of the intake pressure regulator (26), and the exhaust pressure sensor (38) is adapted to detect a second measured pressure value of the exhaust pressure regulator (210). The control module is communicatively connected to the measurement module, the air intake component, the first air extraction component, and the second air extraction component. The control module compares the first measured pressure value with the target altitude pressure value at the air intake end to obtain a first comparison result. Based on the first comparison result, the control module controls the air intake volume of the air intake component and the air extraction volume of the first air extraction component to stabilize the pressure of the air intake pressure stabilizing tank (26) at the target altitude pressure at the air intake end. The control module also compares the second measured pressure value with the target altitude pressure value at the exhaust end to obtain a second comparison result. Based on the second comparison result, the control module controls the air extraction volume of the second air extraction component to stabilize the pressure of the exhaust pressure stabilizing tank (210) at the target altitude pressure value at the exhaust end.

2. The centrifugal compressor high-altitude environment dynamic simulation test system according to claim 1, characterized in that, It also includes a heat exchanger (27), which is located on the intake pipe (11) downstream of the intake pressure tank (26). The heat exchanger (27) is communicatively connected to the control module. The control module compares the temperature of the heat exchanger (27) with the target intake temperature and adjusts the temperature of the heat exchanger according to the comparison result so that the temperature of the heat exchanger is stable at the target intake temperature.

3. The centrifugal compressor high-altitude environment dynamic simulation test system according to claim 1, characterized in that, The air intake assembly includes a fan (21) and a pressure stabilizing chamber (23). The fan (21) is connected to the air intake pressure stabilizing tank (26) through an air intake pipe, and the pressure stabilizing chamber (23) is located on the air intake pipe.

4. The centrifugal compressor high-altitude environment dynamic simulation test system according to claim 3, characterized in that, The air intake assembly also includes an air replenishment valve (22), which is located between the pressure stabilizing chamber (23) and the fan (21).

5. The centrifugal compressor high-altitude environment dynamic simulation test system according to claim 1, characterized in that, The first suction assembly includes a first vacuum pump (24) and a first suction regulating valve (25). The first vacuum pump (24) is connected to the inlet pressure stabilizing tank (26) through a first suction pipeline. The first suction regulating valve (25) is located on the first suction pipeline downstream of the inlet pressure stabilizing tank (26). The second suction assembly includes a second vacuum pump (28) and a second suction regulating valve (29). The second vacuum pump (28) is connected to the exhaust pressure stabilizing tank (210) through a second suction pipeline. The second suction regulating valve (29) is located on the second suction pipeline downstream of the exhaust pressure stabilizing tank (210).

6. The centrifugal compressor high-altitude environment dynamic simulation test system according to any one of claims 1 to 5, characterized in that, An exhaust cooler (211) is provided downstream of the exhaust pipe (15), and the exhaust cooler (211) is connected to a cold water tank (212).

7. The centrifugal compressor high-altitude environment dynamic simulation test system according to any one of claims 1 to 5, characterized in that, The compressor test module also includes an intake rectification system (12), which is located at the downstream end of the intake pipe (11) and upstream of the centrifugal compressor (13).

8. A method for dynamic simulation testing of a centrifugal compressor in a high-altitude environment, characterized in that, include: Set the target altitude and determine the corresponding target altitude pressure value based on the standard atmospheric model; The high-altitude environment simulation module is activated to extract air from the intake pressure tank (26) and the exhaust pressure tank (210) respectively to establish the low-pressure basic environment required by the system. Acquire the first measured pressure value detected by the intake pressure sensor (37) and the second measured pressure value detected by the exhaust pressure sensor (38); The first measured pressure value and the second measured pressure value are compared with the target altitude pressure value to obtain a first comparison result; Based on the first comparison result, the intake volume of the intake assembly into the intake pressure stabilizing tank (26) and the extraction volume of the first extraction assembly into the intake pressure stabilizing tank (26) and the extraction volume of the second extraction assembly into the exhaust pressure stabilizing tank (210) are controlled to dynamically adjust the total airflow into the system and balance the extraction volume, so that the pressure of the intake pressure stabilizing tank (26) and the exhaust pressure stabilizing tank (210) is stabilized at the target altitude pressure value.

9. The method for dynamic simulation test of centrifugal compressor in high-altitude environment according to claim 8, characterized in that, Also includes: Determine the target intake temperature corresponding to the target altitude value; Obtain the heat exchanger temperature; The heat exchanger temperature is compared with the target inlet air temperature to obtain a second comparison result; Adjust the temperature of the heat exchanger according to the second comparison result so that the temperature of the heat exchanger is stable at the target inlet air temperature.

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