A method for testing the function and force-thermal bearing capacity of an interstage structure of an aircraft

Abstract

The application discloses a kind of aircraft interstage structure function and force thermal bearing capacity test method, it is related to aerospace aircraft ground test technical field;With test piece, force thermal test device and push test device are applied, test piece includes interstage support frame, interstage push module and upper stage cabin section;Force thermal test device is used to simulate the complex force thermal comprehensive environment that aircraft interstage section bears, and the structural response of test piece is measured;Push test device is used to verify the feasibility of interstage push module parameter design, and the coordination of separation movement is observed;The application realizes that in ground laboratory environment, simulated flight force, thermal load is simultaneously or continuously applied to interstage section structure, and after preset load environment examination is completed, real push separation mechanism work and the dynamic motion process of upper stage are triggered and tested immediately;This fills the key gap between two-level orbiting interstage section from component static strength examination to system dynamic function verification.

Description

A Test Method for the Functional and Mechanical-Thermal Load-Bearing Capacity of Interstage Structures in Aircraft Technical Field

[0001] This invention relates to the field of ground testing technology for aerospace vehicles, and in particular to a method for testing the inter-stage structural function and mechanical and thermal load-bearing capacity of a vehicle. Background Technology

[0002] Existing technologies have significant limitations in verifying the interstage separation process of horizontal takeoff and landing (FTLR) two-stage-to-orbit vehicles. Interstage separation is one of the riskiest and most dynamically complex stages in the entire mission chain, involving the coupling effects of extreme aerodynamic forces, aerothermal forces, and inertial loads, resulting in highly nonlinear and uncertain separation dynamics.

[0003] Existing numerical simulation analysis is limited by the accuracy of physical models and boundary conditions, making it difficult to accurately simulate nonlinear behavior; aerodynamic wind tunnel tests are limited by model size and test time, making it impossible to finely simulate mechanism details and long-term force and heat load accumulation; full-scale ground functional / static tests suffer from the defects of isolated, static and decoupled tests, making it impossible to reproduce the changes in mechanism performance and complex dynamic interactions under real force and heat loads.

[0004] Therefore, engineering practice urgently needs an integrated test device that can simulate the comprehensive force and thermal load environment before separation in a ground laboratory environment, and can evaluate the dynamic working performance of the separation mechanism (especially the thrust device) and the separation process under this environment, in order to fill the critical gap between component testing and flight verification. Summary of the Invention

[0005] In order to simulate the dynamic process of interstage separation on the ground, verify the feasibility of the thrust device parameter design, and observe the coordination of separation motion, this application provides a test method for the structural function and mechanical and thermal bearing capacity of interstages of an aircraft.

[0006] This application provides a method for testing the inter-stage structural function and mechanical and thermal bearing capacity of an aircraft, employing the following technical solution:

[0007] A method for testing the interstage structure function and thermal load-bearing capacity of an aircraft, characterized in that: a test piece, a thermal assessment test device, and a thrust test device are used; the test piece includes an interstage support frame, an interstage thrust module, and an upper stage section; the interstage support frame is connected to the upper stage section, and the interstage thrust module is set between the interstage support frame and the upper stage section to drive the two to separate.

[0008] The mechanical and thermal testing device includes a test frame, an oven, axial force cylinders, normal force cylinders, axial force blocks, normal force blocks, and various measurement and sensing devices. It is used to simulate the complex mechanical and thermal environment that the interstage section of an aircraft experiences before separation and to measure the structural response of the test piece under this environment.

[0009] The thrust test apparatus includes a hoisting platform and a fall arrestor. The fall arrestor is installed on the hoisting platform and connected to the upper stage section. During the testing of the interstage thrust module, it is used to prevent the upper stage section from falling freely and impacting the test frame after rising. The thrust test apparatus is used to verify the feasibility of the interstage thrust module parameter design and to observe the coordination of the separation motion.

[0010] Optionally, the normal force-applying cylinder applies normal pressure to the upper stage section through the normal force-applying block; the normal force-applying cylinder is installed on the top of the test frame, the two ends of the normal force-applying block are inner arc-shaped blocks with curvature matching the upper stage section, the top of the two inner arc-shaped blocks are connected to a normal force-applying plate, the telescopic end of the normal force-applying cylinder is connected to the normal force-applying plate, and the normal force-applying plate is also provided with reinforcing ribs.

[0011] Optionally, the axial force-applying cylinder applies axial force to the upper stage section via an axial application block. The axial application block consists of an inner clamping plate, an outer clamping plate, a cylinder connecting stud, and a limiting screw. The inner clamping plate is arranged parallel to the outer clamping plate, and the inner clamping plate is used to abut against the upper stage section. The inner clamping plate and the outer clamping plate are connected by the limiting screw. The cylinder connecting bolt is set on the outer clamping plate. The axial force-applying cylinder is fixedly connected to the test frame, and its telescopic end is connected to the cylinder connecting bolt.

[0012] Optionally, the heating oven is located at the lower part of the test frame. The test piece is placed in the heating oven, which can heat the key parts of the test piece to create a controllable high-temperature environment to simulate the thermal load conditions during flight.

[0013] Optionally, the interstage support frame consists of an outer reinforcing plate, an interstage load-bearing block, and an explosive bolt collection box. The outer reinforcing plate and the interstage load-bearing block form a frame with an open top. The top of the interstage load-bearing block is connected to the upper stage section through explosive bolts and shear pins. The bottom of the frame is connected to the test bench. The interstage push-impact module is set in the frame. As an interstage load-bearing structure, the interstage support frame is mainly used to bear the force loads in multiple directions between the interstages before separation.

[0014] Optionally, the upper stage section consists of an inner frame, an outer frame, a middle frame, stringers, and a skin. The outer frame, middle frame, and inner frame are arranged parallel to each other and spaced apart. The stringers are used to connect the three together. The middle frame has a counterweight interface, which can be used to adjust the mass of the upper stage section by adding external counterweights. The upper part of the upper stage section is connected to the normal force plate, and the lower part is connected to the interstage support frame through explosion bolts and shear pins, and is also connected to the axial force application block.

[0015] Optionally, the interstage thrust module consists of a thrust cylinder and a thrust block, used to apply thrust force to the upper stage section to assist in separation; the thrust cylinder is located inside the interstage support frame, and its telescopic end is connected to the thrust block, which abuts against the upper stage section.

[0016] Optionally, the fall arrestor consists of a small wheel, a large wheel, a one-way bearing, a shaft, a one-way bearing mounting base, a fall arrestor mounting plate, a cable, and a tension spring. One end of the cable is fixed to the top of the test piece, and the other end is wound around the large wheel. A rope is wound around the small wheel, and one end of the rope is connected to the tension spring. During operation, when the thrust cylinder drives the upper stage section to move upward, the cable connected to the large wheel changes from taut to slack, and its tension disappears. At the same time, the tension spring connected to the small wheel retracts from its extended state, causing the small wheel, the shaft, and the coaxially fixed large wheel to rotate synchronously in the forward direction, thereby winding and retrieving the cable. When the upper stage section exhausts its kinetic energy and reaches the critical moment of its motion peak and begins to fall, the downward trend will pull the cable, attempting to drive the large wheel to rotate in the opposite direction. At this time, the one-way bearing plays a role in locking the large wheel, preventing it from rotating in the opposite direction, causing the cable to tighten instantly, thereby reliably stopping the upper stage section and suspending it in the air, completing the safety braking.

[0017] Optionally, to accurately quantify the thrust effect, key parameters are measured simultaneously during the thrust test; displacement detection measures the maximum rise height by sensors arranged on the front and rear frames of the upper stage section to directly assess whether the thrust energy is sufficient; acceleration detection captures the maximum acceleration at the initial moment of thrust by sensors arranged in the same position to infer the instantaneous thrust force and impact characteristics.

[0018] By reproducing the complete separation time sequence and dynamic environment, motion response data under the thrust parameters can be directly obtained and analyzed, thereby providing reliable experimental support for judging the rationality of the thrust scheme and optimizing the design parameters, and effectively reducing the risk of engineering development.

[0019] In summary, this application includes the following beneficial technical effects:

[0020] This application utilizes an integrated testing device to simultaneously or continuously apply simulated flight forces and thermal loads (simulating the state before separation) to the interstage structure in a ground-based laboratory environment. After the preset load environment test is completed, the actual operation of the thrust separation mechanism and the dynamic motion process of the upper stage are immediately triggered and tested (simulating the state during separation). This fills a critical gap between component static strength testing and system dynamic function verification. Attached Figure Description

[0021] Figure 1 is an overall structural diagram of the test specimen in this application;

[0022] Figure 2 is an overall structural diagram of the inter-level support frame in Figure 1;

[0023] Figure 3 is an overall structural diagram of the upper stage section in Figure 1;

[0024] Figure 4 is an overall structural diagram of the interstage push-impact module in Figure 1;

[0025] Figure 5 is an overall structural diagram of the mechanical and thermal testing apparatus in this application;

[0026] Figure 6 is an overall structural diagram of the normal force-applying block in Figure 5;

[0027] Figure 7 is an overall structural diagram of the axial force-applying block in Figure 5;

[0028] Figure 8 is an overall structural diagram of the push-impact test device in this application;

[0029] Figure 9 is an overall structural diagram of the fall protection device in Figure 8.

[0030] Explanation of reference numerals in the attached figures:

[0031] 1. Test Specimen; 11. Interstage Support Frame; 111. Outer Reinforcing Plate; 112. Interstage Load-Bearing Block; 113. Explosion Bolt; 12. Interstage Push-Thrust Module; 121. Push-Thrust Cylinder; 122. Push-Thrust Block; 13. Upper Stage Section; 131. Inner Frame; 132. Outer Frame; 133. Middle Frame; 134. Truss; 135. Counterweight Interface; 2. Force and Heat Testing Device; 21. Test Stand; 22. Normal Force Cylinder; 23. Axial Force Cylinder; 24. 241. Normal force-applying block; 242. Inner arc-shaped block; 243. Normal force-applying plate; 2444. Reinforcing rib; 25. Axial force-applying block; 251. Inner side clamping plate; 252. Outer side clamping plate; 253. Cylinder connecting bolt; 254. Limiting screw; 26. Heating oven; 3. Push-impact test device; 31. Lifting platform; 32. Fall protection device; 321. Small wheel; 322. Large wheel; 323. One-way bearing; 324. Rotating shaft; 325. Cable; 326. Tension spring. Detailed Implementation

[0032] The present application will be further described in detail below with reference to Figures 1-9.

[0033] This application discloses a method for testing the functional and thermal load-bearing capacity of an interstage structure in an aircraft. The method utilizes a test piece 1, a thermal load-bearing test device 2, and a thrust test device 3. The test piece 1 is used to simulate the interstage structure of an aircraft. Through the thermal load-bearing test device 2 and the thrust test device 3, the load-bearing capacity of the interstage structure under simulated aerodynamic and thermal coupling loads can be assessed under ground conditions, and the initial separation dynamics of the two-stage aircraft under the design thrust parameters can be tested. This forms a design iteration and closed-loop verification process supported by ground tests, significantly reducing the technical risks of engineering development.

[0034] Referring to Figure 1, in this embodiment of the application, the test piece 1 includes an interstage support frame 11, an interstage thrust module 12, and an upper stage section 13. The interstage support frame 11 is connected to the upper stage section, and the interstage thrust module 12 is disposed between the interstage support frame 11 and the upper stage section 13 to drive the two to separate.

[0035] Referring to Figure 2, the interstage support frame 11 consists of an outer reinforcing plate 111, an interstage load-bearing block 112, and an explosion bolt 113 collection box. The outer reinforcing plate 111 and the interstage load-bearing block 112 form a frame with an open top. The top of the interstage load-bearing block 112 is connected to the upper stage section 13 through explosion bolts 113 and shear pins. The bottom of the frame is connected to the test bench. The interstage push-impact module 12 is set in the frame. The interstage support frame 11, as an interstage load-bearing structure, is mainly used to bear the force loads in multiple directions between the interstages before separation.

[0036] Referring to Figure 3, the upper stage section 13 consists of an inner frame, an outer frame 132, a middle frame 133, stringers 134, and a skin. The outer frame 132 and the middle frame 133 are arranged parallel to and spaced apart from the inner frame. The stringers 134 are used to connect the three together. The middle frame 133 has a counterweight interface 135, which can adjust the mass of the upper stage section 13 by adding external counterweights. It is connected to the interstage support frame 11 below by explosion bolts 113 and shear pins.

[0037] Referring to Figure 4, the interstage thrust module 12 consists of a thrust cylinder 121 and a thrust block 122, which is used to apply thrust force to the upper stage section 13 to assist in separation. The thrust cylinder 121 is located inside the interstage support frame 11, and its telescopic end is connected to the thrust block 122, which abuts against the upper stage section 13.

[0038] Referring to Figure 5, the force and heat test device 2 includes a test frame 21, on which a heating oven 26, an axial force cylinder 23 and a normal force cylinder 22 are installed to simulate the complex force and heat environment that the interstage section of the aircraft is subjected to before separation.

[0039] Referring to Figure 6, the normal force-applying cylinder 22 applies normal pressure to the upper stage section 13 through the normal force-applying block 24; the normal force-applying cylinder 22 is installed on the top of the test frame 21, and the two ends of the normal force-applying block 24 are inner arc blocks 241 with curvature matching the upper stage section 13. The top of the two inner arc blocks 241 are connected to the normal force-applying plate 242. The telescopic end of the normal force-applying cylinder 22 is connected to the normal force-applying plate 242, and the normal force-applying plate 242 is also provided with reinforcing ribs 243.

[0040] Referring to Figure 7, the axial force-applying cylinder 23 applies axial force to the upper stage section 13 through the axial application block. The axial application block consists of an inner clamping plate 251, an outer clamping plate 252, a cylinder connecting stud, and a limiting screw tube 254. The inner clamping plate 251 and the outer clamping plate 252 are arranged parallel to each other. The inner clamping plate 251 is used to abut against the axial end of the upper stage section 13. The inner clamping plate 251 and the outer clamping plate 252 are connected by the limiting screw tube 254. The cylinder connecting bolt 253 is set on the outer clamping plate 252. The axial force-applying cylinder 23 is fixedly connected to the test frame 21, and its telescopic end is connected to the cylinder connecting bolt 253.

[0041] The heating oven 26 is located at the lower part of the test frame 21, and the test piece 1 is placed in the heating oven 26.

[0042] The above structures work together to apply concentrated or distributed forces of adjustable magnitude from different directions to the test piece 1 fixed on the base, so as to reproduce the coupling effect of aerodynamic load and inertial force; at the same time, they reproduce the aerodynamic heating effect of the interstage section during flight. The heating oven 26 can heat the key parts of the test piece 1 (such as the interstage support structure and connection area), creating a controllable high-temperature environment to simulate the thermal load conditions during flight.

[0043] In order to collect experimental data, the following are also included:

[0044] Temperature sensors are placed on the outer wall of the thrust cylinder 121, the interstage support frame 11, and the middle frame 133 of the upper stage section 13, etc., to monitor the temperature field distribution of the structure.

[0045] Displacement sensors are placed on the normal force application plate, the connection between the upper stage section 13 and the interstage support frame 11, etc., to measure the deformation and displacement of the structure under load.

[0046] Strain sensors are located near the bottom left and right beams, front and rear frames, and the connection points with the interstage support frame 11 of the upper stage section 13. They directly measure the strain of key structural components to analyze stress conditions.

[0047] By coordinating and controlling the loading and support structure system and the thermal environment simulation system, multi-directional mechanical and thermal loads simulating real-world working conditions can be applied to test specimen 1 synchronously or sequentially. During this process, the measurement and sensing system collects temperature, displacement, and strain data at key locations on test specimen 1 in real time and synchronously. Through comprehensive analysis of this data, the structural integrity, stiffness characteristics, thermal load-bearing capacity, and connection reliability of test specimen 1 under a force-thermal coupling environment can be objectively evaluated, thereby determining whether its design meets the requirements.

[0048] The thrust test device 3 includes a hoisting platform 31 and a fall arrestor 32. The fall arrestor 32 is installed on the hoisting platform 31 and is connected to the upper stage section 13 via a traction rope. It is used to prevent the upper stage section from falling during the testing of the interstage thrust module 12. The thrust test device 3 is used to verify the feasibility of the parameter design of the interstage thrust module 12 and to observe the coordination of the separation motion.

[0049] Specifically, the fall arrestor 32 consists of a small rotating wheel 321, a large rotating wheel 322, a one-way bearing 323, a rotating shaft 324, a one-way bearing 323 mounting base, a fall arrestor mounting plate, a cable 325, and a tension spring. One end of the cable 325 is fixed to the top of the test piece 1, and the other end is wrapped around the large rotating wheel 322. A rope is wound around the small rotating wheel 321, and one end of the rope is connected to the tension spring. During operation, when the thrust cylinder 121 drives the upper stage section 13 to move upward, the cable 325 connected to the large rotating wheel 322 changes from taut to slack, and its tension disappears. At the same time, the cable 325 connected to the small rotating wheel 321... The tension spring connected to 321 retracts from its extended state, causing the small wheel 321, the shaft 324, and the coaxially fixed large wheel 322 to rotate synchronously in the forward direction, thereby winding and retrieving the cable 325. When the upper stage section 13 exhausts its kinetic energy and reaches the critical moment of its motion peak and begins to fall, the downward trend will pull the cable 325, attempting to drive the large wheel 322 to rotate in the opposite direction. At this time, the one-way bearing 323 plays a role in locking the large wheel 322, preventing it from rotating in the opposite direction, causing the cable 325 to tighten instantly, thereby reliably stopping the upper stage section 13 and suspending it in the air, completing the safety braking.

[0050] The test process rigorously simulated the separation sequence. First, during the unlocking phase, the explosive bolt 113 in test piece 1 detonated upon receiving an electrical signal, releasing the mechanical connection between the upper stage section 13 and the interstage support frame 11. Immediately following, the thrust phase began, with the thrust cylinder 121 instantaneously inflating. Its cylinder rod drove the thrust block 122 upwards, applying a preset instantaneous thrust force to the upper stage section 13. Next came the motion and deceleration phase. After receiving the thrust force, the upper stage section 13 accelerated upwards, causing the top fall arrestor connecting plate to move along with it. At this time, the fall arrestor cable 325 contracted synchronously. When the section's upward kinetic energy was exhausted, the fall arrestor cable 325 immediately locked, safely suspending it in the air, thus completely replicating the entire process from separation initiation to the end of the ascent.

[0051] To accurately quantify the thrust effect, key parameters were measured simultaneously during the experiment. Displacement detection, using sensors positioned on the forward and aft frames of upper stage section 13, measured the maximum ascent height to directly assess whether the thrust energy was sufficient. Acceleration detection, using sensors positioned at the same locations, captured the maximum acceleration at the initial moment of thrust, to infer the instantaneous thrust force and impact characteristics.

[0052] This principle-based experimental model can directly acquire and analyze motion response data under the thrust parameters by reproducing the complete separation time sequence and dynamic environment, thereby providing reliable experimental support for judging the rationality of the thrust scheme and optimizing the design parameters, and effectively reducing the risk of engineering development.

[0053] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A method for testing the inter-stage structural function and mechanical and thermal load-bearing capacity of an aircraft, characterized in that: The application includes test specimens, a force and heat testing device, and a thrust testing device. The test specimens include an interstage support frame, an interstage thrust module, and an upper stage section. The interstage support frame connects to the upper stage section, and the interstage thrust module is positioned between the interstage support frame and the upper stage section to drive their separation. The force and heat testing device includes a test frame, a heating oven, axial force cylinders, normal force cylinders, axial force blocks, normal force blocks, and various measuring and sensing devices. It is used to simulate the complex force and heat environment experienced by the interstage section of the aircraft before separation and to measure and test... The structural response of the component under this environment; the thrust test device includes a hoisting platform and a fall arrestor, the fall arrestor is installed on the hoisting platform and connected to the upper stage section; during the testing of the interstage thrust module, it is used to prevent the upper stage section from falling freely and impacting the test frame after rising; the thrust test device is used to verify the feasibility of the interstage thrust module parameter design and observe the coordination of the separation motion; the upper stage section consists of an inner frame, an outer frame, a middle frame, stringers, and a skin, with the outer frame, middle frame, and inner frame arranged parallel and spaced apart, and the stringers used to connect the three. The components are connected together, with a counterweight interface in the middle frame. The mass of the upper stage section is adjusted by adding external counterweights. The upper stage section is connected to the normal force-applying plate at the top and to the interstage support frame at the bottom via expansion bolts and shear pins, and is also connected to the axial force-applying block. The interstage support frame consists of an outer reinforcing plate and interstage load-bearing blocks, forming a frame with an open top. The top of the interstage load-bearing blocks is connected to the upper stage section via expansion bolts and shear pins, and the bottom of the frame is connected to the test bench. The interstage thrust... The module is set in the frame; the interstage thrust module consists of a thrust cylinder and a thrust block, used to apply thrust force to the upper stage section to assist separation; the thrust cylinder is set inside the interstage support frame, and its telescopic end is connected to the thrust block, which abuts against the upper stage section; the normal force cylinder applies normal pressure to the upper stage section through the normal force block; the normal force cylinder is installed on the top of the test frame; the axial force cylinder is fixedly connected to the test frame, and applies axial force to the upper stage section through the axial application block.

2. The method for testing the inter-stage structural function and mechanical and thermal bearing capacity of an aircraft according to claim 1, characterized in that: The two ends of the normal force-applying block are inner arc-shaped blocks with curvature matching the upper stage section. The top of the two inner arc-shaped blocks are connected to a normal force-applying plate. The telescopic end of the normal force-applying cylinder is connected to the normal force-applying plate. The normal force-applying plate is also provided with reinforcing ribs.

3. The method for testing the inter-stage structural function and mechanical and thermal bearing capacity of an aircraft according to claim 2, characterized in that: The axial application block consists of an inner clamping plate, an outer clamping plate, a cylinder connecting stud, and a limiting screw. The inner clamping plate and the outer clamping plate are arranged in parallel. The inner clamping plate is used to abut against the upper stage section. The inner clamping plate and the outer clamping plate are connected by the limiting screw. The cylinder connecting bolt is set on the outer clamping plate. The telescopic end of the axial force application cylinder is connected to the cylinder connecting bolt.

4. The method for testing the inter-stage structural function and mechanical and thermal bearing capacity of an aircraft according to claim 3, characterized in that: The heating oven is located at the bottom of the test frame, and the test pieces are placed in the heating oven.

5. The method for testing the inter-stage structural function and mechanical and thermal bearing capacity of an aircraft according to claim 4, characterized in that: The fall arrestor consists of a small wheel, a large wheel, a one-way bearing, a shaft, a one-way bearing mounting base, a fall arrestor mounting plate, a cable, and a tension spring. One end of the cable is fixed to the top of the test piece, and the other end is wound around the large wheel. A rope is wound around the small wheel, and one end of the rope is connected to the tension spring. During operation, when the push cylinder drives the upper stage section to move upward, the cable connected to the large wheel changes from taut to slack, and its tension disappears. At the same time, the tension spring connected to the small wheel retracts from its extended state, causing the small wheel, the shaft, and the coaxially fixed large wheel to rotate synchronously in the forward direction, thereby winding and retrieving the cable.

6. The method for testing the inter-stage structural function and mechanical and thermal bearing capacity of an aircraft according to claim 5, characterized in that: To accurately quantify the thrust effect, key parameters were measured simultaneously during the thrust test. Displacement detection used sensors placed on the front and rear frames of the upper stage section to measure the maximum rise height, directly assessing whether the thrust energy was sufficient. Acceleration detection used sensors placed at the same locations to capture the maximum acceleration at the initial moment of thrust, in order to infer the instantaneous thrust force and impact characteristics.

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