Simulation verification system and verification method of aero-engine rotor blade arrangement optimization algorithm

Abstract

In order to solve the problem of low feasibility of verifying a rotor blade arrangement optimization algorithm on an original machine, the invention provides a simulation verification system and method for an aero-engine rotor blade arrangement optimization algorithm, and the verification system comprises a hardware end and a software end. The hardware end comprises a simulation impeller system and a simulation measurement and control system and is used for simulating an impeller system and a measurement and control system of an engine; wherein the simulation impeller system and the simulation measurement and control system are respectively built on the stator rack; and the software end is used for verifying the vibration reduction effect of the engine rotor blade arrangement optimization algorithm according to the vibration value of the rotor system after simulation blade arrangement optimization. By using the simulation experiment method, parts of the aero-engine do not need to be actually disassembled, damage to the real engine is avoided, the verification time is saved, and the efficiency of verifying the feasibility and effectiveness of the engine rotor blade arrangement optimization algorithm is improved.

Description

Technical Field

[0001] This invention relates to the field of aero-engine impeller balancing, and in particular to a verification system and method for an aero-engine rotor blade arrangement optimization algorithm. Background Technology

[0002] Following the gas flow direction, a gas turbine aero engine consists of an intake, compressor, combustion chamber, turbine, and exhaust system connected sequentially. The compressor and turbine are impeller machines, typically composed of alternating stages of working impellers and stationary components. Each working impeller is formed by an inner disk (or drum) and several circumferentially distributed rotor blades on its outer edge. Axial connection of multiple stages of working impellers forms an axial-flow compressor rotor or turbine rotor of a certain length. During engine operation, the rotor rotates at high speed; even a slight eccentric moment can cause strong, or even destructive, vibrations throughout the engine.

[0003] In existing technologies, during the assembly process of aero-engines at the manufacturing plant, in order to improve the internal bending moment phenomenon and reduce the unbalanced torque, it is often necessary to adopt a step-by-step balancing method. That is, during the assembly process, balancing is performed after each stage of impeller is assembled, and then overall mechanical balancing is performed after the rotor is fully assembled. After the impeller (or drum) is manufactured, its center of gravity is not adjustable; however, for the rotor blades, due to manufacturing errors, the mass or mass moment of each blade (considering the mass of short blades and the mass moment of long blades, i.e., the blade mass multiplied by the distance from the blade's center of gravity to the center of rotation) cannot be exactly the same. In order to ensure that the resultant vector of the mass or mass moment of all blades in a certain stage on the plane perpendicular to the axis of rotation (i.e., the resultant vector projected onto the center of rotation) is as small as possible, the circumferential position of the blades needs to be arranged reasonably.

[0004] The traditional method to solve this problem is to group and arrange the blades: before assembling the rotor blades of a certain stage of the impeller of a certain type of engine, weigh each blade and label it with a number; arrange the blades in order of mass size, and adjust the installation position of the rotor blades in the circumferential direction according to the symmetry of mass, so as to minimize the resultant mass vector of all blades in this stage projected to the center of rotation, so as to reduce the imbalance caused by blade assembly.

[0005] It is evident that this method is relatively effective when the number of blades is small; however, in most cases, the number of rotor blades in a certain stage of the impeller is quite large, ranging from more than twenty to over one hundred. The grouping arrangement method is not only inefficient, but also usually fails to find an arrangement scheme that minimizes the resultant mass vector of the blades. In fact, blade arrangement is a typical combinatorial optimization problem that minimizes the objective function value; when the number of blades is n, the algorithm complexity is n!. With the development of computer technology, it has become possible to use various heuristic algorithms to find the optimal solution, such as genetic algorithms, ant colony algorithms, annealing parent algorithms, etc., or improved algorithms based on these algorithms, thereby minimizing the resultant mass vector of all blades projected onto the center of rotation in a certain stage of the impeller. In the process of algorithm improvement research and the development of blade arrangement software for a specific model, the optimization effect of the algorithm or software needs to be verified. One approach is to directly utilize the vibration values ​​of a real, assembled engine within its operating speed range for verification. However, this method has drawbacks: it is costly, as each test run consumes at least one cycle of the engine's lifespan, and most laboratories and universities lack the necessary experimental conditions. For algorithm research and software development, unsatisfactory blade arrangement or omissions in the operational steps on the actual engine could cause significant and destructive vibrations, resulting in unnecessary damage. Disassembling and assembling engine blades is cumbersome, involving components such as the casing, blade disk connectors, and the blades themselves; completely disassembling and assembling an entire stage of blades is time-consuming. Starting and stopping the engine requires specialized technical support, and unauthorized personnel cannot operate it. These drawbacks reduce the feasibility of verifying rotor blade arrangement optimization algorithms on the original engine. Therefore, there is an urgent need for a verification system and method that can improve the feasibility of verifying engine rotor blade arrangement optimization algorithms. Summary of the Invention

[0006] Therefore, it is necessary to provide a simulation verification system and verification method for an aero-engine rotor blade arrangement optimization algorithm that can improve the feasibility and effectiveness of verifying the algorithm.

[0007] Technical Approach: This method employs simulation experiments to verify the effectiveness of the engine rotor blade arrangement optimization algorithm without actually disassembling aero-engine components. The simulation verification system based on the engine rotor blade arrangement optimization algorithm consists of hardware and software components. The hardware component simulates the engine's impeller system and measurement and control system. The impeller system includes a drive motor, a disc with circumferentially distributed holes on its outer edge, and a screw and nut assembly installed in the holes on the outer edge of the disc to simulate rotor blades. The number of holes on the outer edge of the disc corresponds to the number of rotor blades on a real engine impeller. Different masses of rotor blades are simulated by changing the type and number of screws and nuts in the screw and nut assembly. The measurement and control system includes a speed sensor to acquire the disc's rotational speed, a vibration sensor to acquire the radial vibration value of the rotor system during operation, a serial monitor, and a speed control device. The software component processes the signals measured by the sensors and sends the processed speed and vibration values ​​to the tachometer and serial monitor for indication, respectively. By comparing the vibration values ​​of the rotor system before and after the optimization of the simulated blade arrangement (i.e., the simulated impeller arranged using the traditional grouping method), the effectiveness of the engine rotor blade arrangement optimization algorithm in achieving significant vibration reduction is verified.

[0008] The technical objective of this invention is achieved through the following technical solution: In a first aspect, the present invention provides a simulation verification system for an optimization algorithm for rotor blade arrangement of an aero-engine, the system comprising a hardware terminal and a software terminal; On the hardware side, there are simulated impeller systems and simulated measurement and control systems, which are used to simulate the impeller system and measurement and control system of an engine; the simulated impeller system and the simulated measurement and control system are respectively built on a stator test bench; On the software side, it is used to verify the vibration reduction effect of the engine rotor blade arrangement optimization algorithm based on the vibration value of the rotor system after the simulation blade arrangement optimization.

[0009] Optionally, the simulated impeller system includes a drive motor, a speed controller, and a simulated impeller, wherein: The simulated impeller includes a simulated impeller disk and a screw and nut assembly installed in the outer edge hole of the simulated impeller disk. The outer edge hole of the simulated impeller disk is opened on the outer edge of the simulated impeller disk and is evenly distributed along the circumference. The number of outer edge holes of the simulated impeller disk is the same as the number of rotor blades on the actual working impeller of the engine under test. The output shaft of the drive motor is connected to the simulated impeller, and the speed controller is electrically connected to the input end of the drive motor.

[0010] Optionally, the measurement and control system includes a remote control handle, a wireless transceiver, a speed sensor, a vibration sensor, a tachometer, a serial port monitor, and a measurement and control motherboard, wherein: The remote control handle is used to send control commands for starting and stopping the drive motor and adjusting its speed. The wireless transceiver is used to receive control commands sent from the remote control handle and send the received control commands to the speed controller. A speed sensor is used to measure the rotational speed of the simulated impeller; Vibration sensors are used to collect radial vibration values ​​of the rotor system under test. A tachometer is used to indicate the rotational speed of the simulated impeller; The serial port monitor is used to burn the measurement and control program to the measurement and control motherboard before the verification experiment, and to display the radial vibration value of the decoded rotor system during the verification experiment. The measurement and control motherboard is used to receive and process photoelectric signals and vibration signals, and send the processed signals to the tachometer or serial port monitor.

[0011] Optionally, the software includes: The verification object module is used to input the simulated blade mass into the aero-engine rotor blade arrangement optimization algorithm and output the optimized arrangement scheme of the simulated blade. The transceiver module is used to receive start / stop control commands and speed regulation control commands of the drive motor via a wireless transceiver, and send the received commands to the speed controller to adjust the speed of the drive motor. The acquisition module is used to control the speed sensor and vibration sensor through the measurement and control motherboard to acquire the simulated impeller speed and the radial vibration value of the rotor system, respectively. The decoding module is used to transmit the simulated impeller speed and radial vibration values ​​of the rotor system back to the measurement and control motherboard for decoding, and display the decoded data through the tachometer and serial port monitor. The assembly / disassembly module is used to assemble simulated blades and to assemble and disassemble simulated impellers according to the layout scheme. The verification module is used to verify the vibration reduction effect of the current aero-engine rotor blade arrangement optimization algorithm.

[0012] Optionally, the verification module is used to compare the vibration values ​​of the rotor system before the optimization of the simulated blade arrangement scheme with the vibration values ​​of the rotor system after the optimization scheme is adopted, and to obtain the final verification result.

[0013] Optionally, the verification module is used to compare the vibration value of the rotor system with the optimized arrangement scheme with a preset vibration threshold to obtain the final verification result.

[0014] Secondly, the present invention provides a simulation verification method for an aero-engine rotor blade arrangement optimization algorithm, which is implemented based on the aforementioned simulation verification system for an aero-engine rotor blade arrangement optimization algorithm. The method includes: The mass of the simulated blades is obtained and input into the verification object module to obtain the optimized arrangement scheme. According to the optimized layout scheme, the simulated blades are sequentially installed into the outer edge holes of the simulated impeller through the disassembly and assembly module to form the optimized simulated impeller. The simulated impeller is then installed at the end of the output shaft of the drive motor to form the optimized rotor system under test. The transceiver module adjusts the speed of the drive motor based on the received start / stop commands and speed adjustment commands. The acquisition module obtains the simulated impeller speed and the radial vibration value of the measured rotor system after the current layout scheme is optimized. Obtain target reference information, compare the radial vibration value of the optimized rotor system under test with the target reference information, and verify the optimization effect of the layout scheme.

[0015] Optionally, obtaining the target reference information involves comparing the radial vibration value of the optimized rotor system under test with the target reference information to verify the optimization effect of the layout scheme, including: The simulated blades were randomly installed in the outer edge holes of the simulated impeller to form the simulated impeller before the arrangement was optimized. The simulated impeller was then installed at the end of the output shaft of the drive motor to form the rotor system under test before optimization. The simulation impeller speed and radial vibration value of the rotor system under the current layout scheme are obtained by the acquisition module, and the radial vibration value of the rotor system under test before optimization is used as the target comparison information. The verification module compares the target reference information at different speeds with the radial vibration value of the optimized rotor system under test. If the radial vibration value is less than the target reference information, the verification is successful and the optimized layout scheme is effective.

[0016] Optionally, obtaining the target reference information involves comparing the radial vibration value of the optimized rotor system under test with the target reference information to verify the effectiveness of the optimized arrangement scheme, including: Determine the vibration threshold and use it as target reference information; The verification module compares the target reference information at different speeds with the radial vibration value of the optimized rotor system under test. If the radial vibration value is less than the target reference information, the verification is successful and the optimized layout scheme is effective.

[0017] Compared with the prior art, the present invention has the following advantages: High cost-effectiveness: By using simulation experiments, there is no need for actual engine driving tests, which saves engine life and greatly reduces the cost of the verification process.

[0018] The method does not affect the engine's continued airworthiness: Since there is no need to actually disassemble the engine, the verification method verifies the applicability and effectiveness of the layout optimization algorithm through simulation experiments, avoiding damage to the real engine and not affecting the engine's continued airworthiness.

[0019] High time efficiency: Compared with the cumbersome process of disassembling and assembling blades on a real engine, the verification method of simulation experiment does not require actual disassembly of aero-engine parts, which can greatly shorten the time of the entire verification process and quickly verify the algorithm effect.

[0020] High academic value: The simulation verification platform does not require professionally authorized personnel to operate the real engine, making it suitable for academic research. This saves human and material resources and improves the feasibility of verifying the engine rotor blade arrangement optimization algorithm.

[0021] High engineering practical value: It provides an algorithm for optimizing rotor blade arrangement, which makes the resultant vector of rotor blade mass or mass moment very small after rearranging according to the optimized scheme, simplifying the subsequent rebalancing work. Attached Figure Description

[0022] Figure 1 A flowchart of the simulation verification method for the optimization algorithm of rotor blade arrangement of aero-engine.

[0023] Figure 2 The architecture diagram of the simulation verification system for the optimization algorithm of rotor blade arrangement of aero-engine.

[0024] Figure 3 This is a schematic diagram of the fan disc structure of the fan impeller of the CFM56-3 engine.

[0025] Figure 4 A flowchart of an algorithm for optimizing the arrangement of rotor blades in an aero-engine.

[0026] Figure 5 This is the main interface of the aero-engine rotor blade arrangement optimization algorithm software.

[0027] Figure 6 This is the interface for the data modification module of the aero-engine rotor blade arrangement optimization algorithm software.

[0028] Figure 7 (a) is a physical image of the hardware of the simulation verification platform.

[0029] Figure 7 (b) is an enlarged view of the simulated impeller and drive motor in the physical drawing.

[0030] Figure 7 (c) is a schematic diagram showing the positions of the control motherboard, vibration sensor, and wireless transceiver in the physical diagram.

[0031] Figure 8 This is a physical image of the remote control handle in the simulation verification system.

[0032] Figure 9A screenshot of the contents of the blade data file "data.xlsx" imported into the aero-engine rotor blade arrangement optimization algorithm software (using the real dataset of the mass moment of the fan rotor blade of CFM56-3 engine as an example).

[0033] Figure 10 The optimized arrangement scheme output by the algorithm software for optimizing the arrangement of rotor blades of aero-engines.

[0034] Figure 11 Screenshot of the contents of the file "result.xlsx" which stores the results of the optimized layout scheme.

[0035] Figure 12 Screenshot of the Arduino IDE program burning result.

[0036] Figure 13 This is the data display interface for the serial port monitor.

[0037] Figure 14 This is a graph showing the vibration values ​​displayed on the serial monitor.

[0038] Figure 15 A visual interface written for LabVIEW. Detailed Implementation

[0039] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims. Example 1

[0040] This application provides a simulation verification system for an engine rotor blade arrangement optimization algorithm. The system includes hardware and software components. The hardware includes a simulation impeller system and a measurement and control system, which are respectively mounted on a stator test bench. Figure 7 As shown, the stator stand is a square frame structure made of metal, used to support and install various components of the impeller system and the measurement and control system.

[0041] (1) Simulated impeller system The simulated impeller system includes a drive motor, a power battery, a speed controller, a simulated impeller, and a semi-enclosed protective net. The drive motor is mounted on one side of the stator frame. One end of the motor is connected to the speed controller, and the other end is connected to the simulated impeller. It is used to control the rotation of the simulated impeller according to the output speed of the speed controller. The power battery is located at the bottom of the stator platform and is connected to the drive motor through a circuit to provide electrical energy to the drive motor. The drive motor converts this electrical energy into mechanical energy to drive the simulated impeller to rotate.

[0042] The speed controller, located at the bottom of the stator platform, is electrically connected to the drive motor and is used to control the speed of the drive motor. The speed controller receives commands from the wireless transceiver and uses PWM (Pulse Width Modulation) signals to adjust the speed of the drive motor and the simulated impeller. PWM reduces the average power transmitted by the electrical signal by dispersing the effective electrical signal into a discrete form.

[0043] The simulated impeller is mounted on one side frame of the stator test stand. It includes a combination of screws and nuts in holes evenly distributed around the outer edge of the simulated impeller. By installing screws and nuts of different masses, it is used to simulate the working impeller of a real engine. The simulated impeller is a rotatable turntable. The rotation center of the simulated impeller is coaxially connected to the power output shaft of the drive motor, which can drive the simulated impeller to rotate. Different masses of real blades are simulated by a combination of screws / nuts. Since the rotation radius of the screw / nut combination around the center of the simulated impeller is the same, their mass is used to replace the mass moment. The semi-enclosed protective net, consisting of an aluminum mesh and an aluminum profile frame, is installed on the outside of the stator platform for safety protection, preventing rotating parts from flying out during the experiment, thereby ensuring the safety of the operators.

[0044] (2) Measurement and control system The measurement and control system includes a DC power supply, a remote control handle, a wireless transceiver, a speed sensor, a vibration sensor, a tachometer, a serial port monitor, and a measurement and control motherboard; The DC power supply, located at the bottom of the stator platform, can use a 3S lithium battery and is connected to the control motherboard (Arduino) via circuitry. It is used to provide working power to the control motherboard (Arduino), wireless transceiver, speed sensor, vibration sensor, and tachometer. The remote control handle is used by the operator to send start / stop and speed adjustment control commands to the drive motor, such as... Figure 8 As shown; the start / stop command and speed adjustment command of the drive motor can control the drive motor to work at the corresponding speed set by the remote control handle; the remote control handle can send the control commands for starting / stopping the drive motor and adjusting its speed to the wireless transceiver via a wireless network; The wireless transceiver is installed on the other side of the stator frame. It is used to receive start and speed adjustment control commands sent by the operator through the remote control handle, and to send the received control commands to the speed controller, which adjusts the speed of the drive motor and the simulated impeller. A speed sensor, mounted on the back of the simulated impeller, is used to measure the speed of the simulated impeller; a reflective photoelectric speed sensor can be used, which determines the speed of the simulated impeller by detecting reflective marks on the rotating parts. The vibration sensor is installed on the outer wall of the stator frame, close to the simulated impeller, to collect the radial vibration value of the rotor system under test. By collecting vibration signals in the X and Y axes, the vibration signals in the X and Y axes are combined into a radial vibration signal of the rotor system, which is used to monitor and analyze the vibration during the experiment. The tachometer is located on the outermost surface of the stator test stand frame and is used to indicate the rotational speed of the simulated impeller. A serial monitor is the measurement and control software and its display window installed on a laptop computer, corresponding to the measurement and control motherboard (Arduino). The serial monitor (laptop) is connected to the measurement and control motherboard (Arduino) via a USB data cable. It is used to burn the measurement and control program to the measurement and control motherboard (Arduino) before the verification experiment, and to display the radial vibration value of the decoded rotor system during the verification experiment. The measurement and control motherboard (Arduino) is installed on the top of the frame of the stator test bench and acts as the brain of the experimental platform to ensure that all components work together. The measurement and control motherboard is the central processing unit, which is used to receive and process photoelectric signals and vibration signals, and send the processed signals to the tachometer or serial monitor and transmit relevant data. Specifically, the wireless transceiver, speed sensor, vibration sensor, tachometer, and serial monitor are electrically connected to the measurement and control motherboard. The photoelectric speed sensor and vibration sensor send photoelectric and vibration signals to the measurement and control motherboard for signal processing, respectively. The measurement and control motherboard sends the processed speed signal to the tachometer for reference when adjusting the speed. The measurement and control motherboard and the serial monitor are connected via a USB data cable. Before the verification experiment, the measurement and control program can be burned to the measurement and control motherboard through the serial monitor. During the verification experiment, the measurement and control motherboard sends the processed vibration signal to the serial monitor for indication.

[0045] Alternatively, data can be displayed using a host computer program written in LabVIEW. The measurement and control motherboard transmits the processed data, such as rotational speed and vibration values, to the host computer via a wireless transceiver for visualization of instrument pointers, curves, etc. Figure 15 As shown, a visualization interface created using LabVIEW is used to display and analyze experimental data in more detail. From Figure 15As can be seen, this visualization interface mainly provides information such as rotational speed and vibration parameters, offering visual results in the form of images and charts to help operators better understand the experimental results. LabVIEW is a program development environment, similar to a C++ development environment. However, a significant difference between LabVIEW and other computer languages ​​is that while other computer languages ​​use text-based languages ​​to generate code, LabVIEW uses the graphical editing language G to write programs, producing programs in the form of block diagrams. Secondly, the software side includes the layout optimization algorithm software used for verification, and the control program for the simulation verification platform. Combined with... Figure 2 The software includes the following modules: (1) Verification object The verification object module is used for optimization algorithm research and algorithm implementation in programming language. It inputs the blade mass or mass moment into the aero-engine rotor blade arrangement optimization algorithm program to be verified and outputs the optimized arrangement scheme of the rotor blades. Specifically, in this invention, the algorithm program or software for optimizing the arrangement of rotor blades of an aero-engine is used as the verification object. By running the program or software, the optimized arrangement scheme of the blades can be output according to the different input blade masses or mass moments. Without loss of generality, the embodiments of this application select an algorithm or software program for optimizing the rotor blade arrangement on the fan impeller of the classic gas turbine fan engine, the CFM56-3 engine, as the verification object. The CFM56-3 engine is the sole power plant of Boeing B737-300 / 400 / 500 aircraft, and its bypass exhaust provides more than 78% of the thrust, which requires a large-diameter fan impeller to generate. A large-diameter fan impeller also has a large moment of inertia, making the balance of the fan impeller particularly important; even a slight imbalance can cause a significant level of engine vibration.

[0046] (2) Control program (2.1) Transceiver module, used to receive drive motor start / stop commands and speed adjustment commands sent by remote control handle through wireless transceiver, and send the received drive motor start / stop commands and speed adjustment commands to speed controller, and use speed controller to adjust drive motor speed; (2.2) Acquisition module, used to control the speed sensor and vibration sensor to acquire the simulated impeller speed and the radial vibration value of the rotor system under test respectively through the measurement and control motherboard when the speed of the drive motor is not zero; (2.3) Decoding module, used to transmit the simulated impeller speed and rotor system radial vibration value back to the measurement and control motherboard for decoding, and display the decoded data through the tachometer and serial port monitor; (2.4) Assembly and disassembly module, used by operators to assemble simulated blades, insert simulated blades into the outer edge holes of the simulated impeller according to the arrangement scheme, or remove simulated blades from the outer edge holes of the simulated impeller, thereby realizing the assembly and disassembly of the simulated impeller; and install the simulated impeller to the end of the output shaft of the drive motor or remove the current simulated impeller from the end of the output shaft of the drive motor; (2.5) Verification module, used to compare the vibration value of the rotor system before and after the optimization of the simulated blade arrangement scheme to verify the optimization and vibration reduction effect of the engine rotor blade arrangement optimization algorithm; or directly test the vibration value of the rotor system after the optimization of the simulated blade arrangement scheme. If the vibration value is lower than the preset vibration threshold, the verification is passed and the arrangement scheme and arrangement optimization algorithm are effective. If it is higher than the preset vibration threshold, the verification is not passed. Example 2

[0047] according to Figure 1 The present invention also provides a simulation verification method for an optimization algorithm for the rotor blade arrangement of an aero-engine, which includes the following steps: Step 1: Prepare a computer-friendly algorithm program or software for optimizing the arrangement of rotor blades for aero-engines; Step 2: Build a simulation verification platform for the optimization algorithm of aero-engine rotor blade arrangement, and burn the control program of the simulation verification platform to the measurement and control motherboard; Step 3: If the wireless transceiver receives the start / stop control and speed adjustment commands for the drive motor from the remote control handle, it will send the commands to the speed controller and use the speed controller to adjust the speed of the drive motor. Step 4: If the drive motor speed is not zero, the speed sensor and vibration sensor are controlled by the measurement and control motherboard to collect the simulated impeller speed and the radial vibration value of the rotor system before and after the optimization of the simulated blade arrangement scheme. In this step, a start / stop control command is issued using the remote control handle. The wireless transceiver receives the control command and controls the rotor system to start up for the first time and increase the speed through the speed controller, thereby obtaining the radial vibration value of the rotor system before the optimization of the simulated blade arrangement at each speed. Similarly, a start / stop control command is issued again using the remote control handle. The wireless transceiver receives the command and controls the rotor system to start up for the second time and increase the speed through the speed controller, thereby obtaining the radial vibration value of the rotor system after the optimization of the simulated blade arrangement at each speed. Specifically, step 4 may include: Step 4.1: Determine the screw type and fit different numbers and sizes of nuts on the screw to form simulated blades of different masses. The number of simulated blades is consistent with the number of rotor blades on the real engine impeller. Step 4.2: Weigh the different simulated blades using a precision balance; Step 4.3: Randomly install simulated blades of different masses into the outer edge holes of the simulated impeller, or calculate the arrangement scheme using the traditional grouping method, and install the simulated blades into the outer edge holes of the simulated impeller according to the arrangement scheme to form the simulated impeller before optimization; at this time, the simulated impeller before optimization has a large imbalance. Step 4.4: Install the simulated impeller before optimization onto the end of the output shaft of the drive motor to form the rotor system under test; Step 4.5: At the current drive motor speed, measure and display the radial vibration value of the rotor system before optimization at the current speed. Step 4.6: Input the mass of different simulated blades into the aero-engine rotor blade arrangement optimization algorithm program or software to obtain the optimized blade arrangement scheme; Step 4.7: Remove the unoptimized simulated impeller from the end of the drive motor output shaft and remove the simulated blades; Step 4.8: Reinstall the simulated blades into the outer edge holes of the simulated impeller according to the optimized blade arrangement scheme to form the optimized simulated impeller; at this time, the imbalance of the optimized simulated impeller is small. Step 4.9: Install the optimized simulated impeller at the end of the drive motor output shaft to form a new rotor system under test; Step 4.10: At the current drive motor speed, measure and display the radial vibration value of the optimized new rotor system under test; Step 5: Compare the radial vibration values ​​before and after optimization. If the radial vibration value after optimization is less than the radial vibration value before optimization, it means that the arrangement scheme output by the aero-engine rotor blade arrangement optimization algorithm to be verified is effective; otherwise, the arrangement scheme is invalid.

[0048] Finally, by comparing the vibration values ​​of the rotor system before and after the optimization of the simulated blade arrangement scheme within the design speed range, the vibration reduction effect of the engine rotor blade arrangement optimization algorithm can be verified, thus improving the feasibility of verifying the rotor blade arrangement optimization algorithm.

[0049] Alternatively, based on a large amount of experimental data, the vibration threshold of the rotor system is determined. In step 5, the radial vibration value of the newly tested rotor system after the optimization of the simulated blade arrangement scheme is directly collected. If the optimized radial vibration value is lower than the preset vibration threshold, the verification is passed and the arrangement scheme is effective; if the optimized radial vibration value is higher than the preset vibration threshold, the verification fails. Example 3

[0050] Combination Figure 4 The present invention also provides an optimization algorithm for the arrangement of aero-engine rotor blades, which is implemented by a genetic algorithm with multiple populations co-evolution to obtain an optimized arrangement scheme for engine rotor blades.

[0051] Taking a single-stage fan rotor as an example, in actual operation, when the blade structure damage exceeds the standard, new rotor blades need to be replaced. Engine manufacturers provide two replacement methods: replacement in pairs or replacement single blades. However, replacing the rotor blades will disrupt the original balance of the impeller. According to the solution provided in the maintenance manual, if the replacement in pairs is used, the engine can be put into operation directly when the number of blade pairs to be replaced is less than or equal to 5 pairs and the change in the resultant vector of the blade mass moment before and after replacement is less than or equal to 50 g·inch; or if the replacement single blade is used, the engine can be put into operation directly when the change in the resultant vector of the blade mass moment before and after replacement is less than or equal to 50 g·inch. Otherwise, the installation positions of all blades need to be rearranged. Therefore, aero-engine rotor blade layout optimization algorithm software becomes an essential tool. In addition to the above situations in engine operation and maintenance that require optimization of the installation positions of all rotor blades on the impeller, new engines or refurbished engines also need to optimize the installation positions of all rotor blades before assembling the impeller during assembly, and calculate the blade installation scheme.

[0052] The fan impeller of the CFM56-3 engine is composed of a fan disc and several rotor blades whose blade root tenons are inserted into mortise grooves on the outer edge of the fan disc. With the engine positioned horizontally along its axis of rotation, and viewed from front to back, the origin O is the center of rotation of the fan impeller. The positive X-axis is horizontally to the right of the origin, and the positive Y-axis is vertically upward. The opening of mortise groove #1 faces the positive X-axis, and the other mortise grooves are numbered counter-clockwise, such as... Figure 3 As shown, the blade installed in tenon 1 is designated as blade 1, the blade installed in tenon 2 as blade 2, and so on. The CFM56-3 engine's fan impeller has 38 rotor blades. The mass moments of each blade (because the blades are relatively long, mass moments are used) are shown in Table 1. Projecting the mass moments of all blades onto the origin yields the resultant vector. In a real engine, this resultant vector is not zero. The purpose of the layout optimization algorithm is to find the blade arrangement scheme that minimizes the resultant vector for the installation positions of these blades, thereby reducing the workload and difficulty of subsequent balancing.

[0053] Table 1 Mass Moment of CFM56-3 Engine Fan Rotor Blades Rotor blade arrangement is a typical combinatorial optimization problem that minimizes the objective function value. It involves large datasets and has an algorithm complexity of O(n log n). This is a nondeterministic polynomial-time problem. When the number of blades is small, it can be solved by enumeration. However, when the number of blades is large, exhaustively searching for all possible arrangements to find the global optimal solution is unacceptable in terms of computational resources and time.

[0054] Genetic algorithms originated from computer simulations of biological evolution. They are a stochastic global search optimization method that simulates the crossover and mutation phenomena that occur in natural selection and heredity. Starting from any random initial population, through random selection, crossover, and mutation operations, a new generation of individuals that are more adapted to the environment is generated. This process continues generation after generation until each individual in the population exhibits the traits most adapted to the environment, thus obtaining a high-quality solution to the problem.

[0055] Therefore, in the embodiments of this application, a genetic algorithm is used as the basis for the optimization algorithm of aero-engine rotor blade arrangement. Since the standard genetic algorithm (SGA) (using only the proportional selection operator) suffers from the problem of good solutions being lost during evolution and failing to achieve global convergence, the arrangement optimization software algorithm in this invention is based on a genetic algorithm with multiple population co-evolutionary mechanisms, such as... Figure 4 As shown, this algorithm adds an elite retention strategy (elite population in the figure) to the standard genetic algorithm, and after a specified number of iterations, it cyclically replaces the worst individual in the population with the best individual, that is, it adopts an individual exchange strategy between populations (migration operator in the figure).

[0056] Among them, the multi-population co-evolutionary genetic algorithm is an evolutionary algorithm based on population cooperation. It optimizes an optimization problem simultaneously using multiple populations in parallel, which can improve the algorithm's efficiency. The elite preservation strategy directly copies the best individual that has emerged in the population during the evolutionary process into the next generation without performing genetic operations, and replaces the worst individual in the next generation with it. The elite preservation strategy improves the global convergence ability of the genetic algorithm, and it has been theoretically proven that the genetic algorithm with elite preservation is globally convergent.

[0057] Combination Figure 4 The present invention provides an optimization algorithm for the rotor blade arrangement of an aero-engine, comprising the following steps: Step 1: Obtain the mass of 38 different simulated blades, and generate an initial population based on the set of blade arrangement schemes with different arrangement orders; Step 2: Use the initial population to randomly generate multiple populations, set the size and number of iterations for each population, and set different crossover and mutation probabilities for each population; Step 3: Traverse all generated populations. Each population is selected, crossovered and mutated using an independent standard genetic algorithm. The migration operator is used to exchange information of the standard genetic algorithm between multiple populations (i.e., replacing the worst individual with the best individual). Step 4: Use a manual selection operator to screen elite populations from multiple populations, and then use the fitness function to calculate the simulated leaf composite vector (i.e., individuals in the elite population) sequentially. Step 5: Determine whether the convergence condition has been met (i.e., the preset number of iterations or the preset upper limit of the sum vector). If it has been met, the best individual of the elite population will be output. If it has not been met, return to step 4. Step 6: Based on the output of the best individual, obtain the optimized blade arrangement order.

[0058] The aero-engine rotor blade arrangement optimization algorithm software, based on the above algorithm, can run on Windows 7 64-bit / Windows 10 64-bit systems. The software's visual interface was developed using Python 3.8 + PySide2, and its main interface is shown below. Figure 5 As shown, the overall layout is grid-like.

[0059] from Figure 5 As can be seen, the main interface of this software includes the following functional modules: ① Data Import Module Clicking "Import Data" allows you to import blade mass or mass moment data and original layout schemes from an Excel file in a specific format. For example, the contents of the imported Excel file data.xlsx might look like this: Figure 9 As shown.

[0060] Click "Clear Data" to clear the data table.

[0061] Clicking "Import Layout" allows you to import other layout schemes from Excel.

[0062] Clicking "Reset Layout" will reset the layout while retaining the mass or mass moment data, allowing you to manually enter a layout scheme.

[0063] ② Data Modification Module Enter the blade number in the blade number field, and its mass or mass moment below. Click "Add Data" to add a blade in the corresponding position on the left. Figure 6 The numbers ① and ② are shown in the diagram. Enter the blade number, and click "Delete Data" to delete the corresponding blade data. Figure 6 The area indicated by serial number ③ is shown in the diagram.

[0064] ③ Parameter setting module exist Figure 5 In the parameter settings area at the bottom left, you can see that "Set the number of iterations" means that the program will terminate after the corresponding number of iterations. The larger the value, the longer the program takes.

[0065] The "Set End Threshold" option is a radio button, which defaults to "No". After clicking the "Yes" button and setting the end threshold on the right, the program will stop running after finding a solution that is not greater than the set threshold. The "Set Random Result" option is a radio button, which defaults to "No". Clicking the "Yes" button will use a random number seed of "1" by default to ensure that the current solution result can be reproduced.

[0066] ④ Result output and saving module Figure 5 The lower right corner contains the results output and saving module, and the progress bar displays the solution progress in graphical and percentage form.

[0067] Click "Run," and the program will start running and display the current solution results in real time. The optimized layout solution results are as follows: Figure 10 As shown.

[0068] Click "Stop" to stop the program. Click "Exit" to exit the program; Clicking "Save" will name the layout result file "result.xlsx" and save it in the corresponding root directory of the program. The specific content of the "result.xlsx" file is as follows: Figure 11 As shown.

[0069] Simulation Experiment To provide a detailed explanation of the operation method of the verification system for the engine rotor blade arrangement optimization algorithm, the following simulation experiment uses a dataset of simulated blade mass (listed in Table 2) as an example to illustrate the operation method of the verification system.

[0070] When using this verification model, the corresponding mass moment data can be replaced with the mass of the simulated blade—that is, the mass of the screw and nut combination. The mass data of the screw and nut combination is shown in Table 2. In use, only the imported mass or mass moment data differs; all other operations are the same. Furthermore, Table 2 lists 30 different masses for the simulated blades formed by the screw and nut combination. During the simulation experiment, in addition to selecting all 30 masses, 8 more masses were selected to form 38 simulated blades, corresponding to the number of fan rotor blades in the actual CFM56-3 engine.

[0071] Table 2. Screw and nut assembly quality data First, import the data. Name the blade data "data.xlsx" and save it in a directory relative to the program. For example... Figure 9 As shown, column A contains the blade's own serial number, column B contains the corresponding blade's mass or moment of mass data, and column C contains the blade's current location number (which can be empty). Click the "Import Data" button and select the "data.xlsx" file to import. Alternatively, you can manually enter the blade serial number, mass, or moment of mass data by clicking the "Add Data" button.

[0072] Next, after importing all blade masses or mass moments and their arrangement, click "Calculate Unbalance" to calculate the resultant vector magnitude of the current blade mass or mass moment. The data used in the calculation is ultimately... Figure 5 The data in the table at the top left are all dimensionless parameters. At the same time, the angle (0-360°, in degrees) between the first position (i.e., the blade in the first position) and the resultant vector of the entire blade stage is calculated in a counterclockwise direction, i.e., the direction of the resultant vector of the entire blade stage.

[0073] Next, set the parameters. Set the number of iterations according to your needs; the default is 200, and this experimental case uses 200 iterations. Set the termination threshold according to your needs; this experimental case selects "Yes" and sets it to 0.5, meaning that the solution will terminate when a result no greater than 0.5 is found, and a message box will pop up, such as "A result meeting the conditions has been found." Set whether to fix the result (optional), which allows you to run the program multiple times to fix the solution result.

[0074] Next, after setting the parameters, click "Run," and the solution results will be displayed. Figure 5 The text box in the lower right corner, the specific solution results are as follows: Figure 10 As shown. Figure 10 As shown, blade number 19 is in the first position, blade number 6 is in the second position, and so on. Figure 10 The mass or mass moment modulus of the arrangement shown is 0.47. Blade number 19 is placed in the first position, and its angle with the resultant vector is 45° in the counterclockwise direction.

[0075] Next, save the results. Clicking the "Save" button will save the optimization results to the "result.xlsx" file in the program's relative directory, and a prompt box will pop up. Arrange the simulation blades according to the saved optimization results, that is, arrange the combination of screws and nuts.

[0076] Next, connect the experimental setup. First, connect the 6S battery to the drive motor via a circuit. You will hear a continuous series of short, sharp "beep" sounds from the drive motor, indicating that the control board is not detected. Next, connect the 3S battery to the control board (Arduino) via a circuit; the 3S battery provides power to the control board. Then, connect the Arduino data cable to the laptop. Finally, you must first... Figure 8 Move the throttle lever (highlighted in the red box on the left) to its lowest position to prevent the motor from suddenly starting and causing a hazard after successful connection. Then, press and hold the power button (highlighted in the red square in the middle of the remote control) for 1 to 3 seconds. The remote control will automatically connect to the wireless transceiver. After successful connection, the drive motor will no longer emit "beep, beep" sounds. The 6S power battery provides electrical energy to the drive motor, which converts this electrical energy into mechanical energy to drive the simulated impeller.

[0077] Next, the program is burned. For example... Figure 12 As shown, after successfully connecting the measurement and control motherboard (Arduino), click Project - Upload in the Arduino IDE menu bar and wait for the program to be successfully burned.

[0078] Next, data collection. For example... Figure 13 As shown, click the serial monitor button in the red box in the upper right corner. The vibration data will then be continuously displayed in the monitor window. Operate the remote control's "throttle lever" to run the equipment; the vibration values ​​will be displayed on the serial monitor. Figure 14 As shown. It is recommended to clear the output when the speed is constant, run for a period of time, and then reverse the automatic scrolling selection to copy the values ​​in the serial port monitor for further data processing.

[0079] Finally, at the drive motor speed, if the radial vibration value is lower than the preset vibration threshold, the verification is passed; if the radial vibration value is higher than the preset vibration threshold, the verification fails.

[0080] In summary, the simulation verification system and verification method for the optimization algorithm of rotor blade arrangement of aero-engine provided by this invention can improve the efficiency of verifying the effectiveness and feasibility of the optimization algorithm of rotor blade arrangement, eliminate the need for actual aircraft experiments, save manpower and material resources, and will not affect the continuous airworthiness of the engine, requiring only one test run.

[0081] Although preferred embodiments of the present application have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the embodiments of the present application.

[0082] Finally, it should be noted that in this text, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or terminal device that includes said element.

[0083] The simulation verification system and verification method for the optimization algorithm of rotor blade arrangement of aero-engine provided in this application have been described in detail above. Specific examples have been used to illustrate the principle and implementation of this application. The description of the above embodiments is only for the purpose of helping to understand the method and core idea of ​​this application. At the same time, for those skilled in the art, there will be changes in the specific implementation and application scope based on the idea of ​​this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. An aeroengine rotor blade arrangement optimization algorithm simulation verification system, characterized in that, The simulation verification system comprises a hardware end and a software end; The hardware end comprises a simulation impeller system and a simulation control system, and is used for simulating the impeller system and the control system of the engine; wherein the simulation impeller system and the simulation control system are respectively built on the stator bench; The software end is used for verifying the vibration reduction effect of the engine rotor blade arrangement optimization algorithm according to the vibration value of the rotor system after the simulation blade arrangement optimization.

2. The system of claim 1, wherein, The simulation impeller system comprises a driving motor, a speed regulator and a simulation impeller, wherein: The simulation impeller comprises a simulation disc and a screw nut combination installed in the simulation disc outer edge hole, the simulation disc outer edge hole is arranged on the outer edge of the simulation disc and is uniformly arranged in the circumferential direction, the number of the simulation disc outer edge hole is the same as the number of the rotor blades on the working impeller of the real engine to be tested; The output shaft of the driving motor is connected with the simulation impeller, and the speed regulator is electrically connected with the input end of the driving motor.

3. The system of claim 2, wherein, The control system comprises a remote control handle, a wireless transceiver, a rotating speed sensor, a vibration sensor, a rotating speed meter, a serial port monitor and a control mainboard, wherein: The remote control handle is used for sending the driving motor start-stop and driving motor rotating speed adjustment control instructions; The wireless transceiver is used for receiving the control instructions sent by the remote control handle and sending the received control instructions to the speed regulator; The rotating speed sensor is used for measuring the rotating speed of the simulation impeller; The vibration sensor is used for collecting the radial vibration value of the rotor system to be tested; The rotating speed meter is used for indicating the rotating speed of the simulation impeller; The serial port monitor is used for burning the control program into the control mainboard before the verification experiment and displaying the decoded radial vibration value of the rotor system in the verification experiment; The control mainboard is used for receiving and processing the photoelectric signal and the vibration signal and sending the processed signals to the rotating speed meter or the serial port monitor.

4. The system of claim 3, wherein, The software end comprises: The verification object module is used for inputting the simulation blade mass into the aero-engine rotor blade arrangement optimization algorithm and outputting the optimized arrangement scheme of the simulation blade; The transceiver module is used for receiving the driving motor start-stop control instruction and the rotating speed adjustment control instruction through the wireless transceiver, sending the received instructions to the speed regulator and adjusting the rotating speed of the driving motor by using the speed regulator; The collection module is used for collecting the rotating speed of the simulation impeller and the radial vibration value of the rotor system by the control mainboard controlling the rotating speed sensor and the vibration sensor respectively; The decoding module is used for returning the rotating speed of the simulation impeller and the radial vibration value of the rotor system to the control mainboard for decoding and displaying the decoded data through the rotating speed meter and the serial port monitor; The disassembly and assembly module is used for combining the simulation blades and combining and disassembling the simulation impeller according to the arrangement scheme; The verification module is used for verifying the optimized vibration reduction effect of the current aero-engine rotor blade arrangement optimization algorithm.

5. The system of claim 4, wherein, The verification module is used for comparing the vibration value of the rotor system before the simulation blade arrangement scheme optimization and the vibration value of the rotor system after the optimized arrangement scheme is adopted to obtain the final verification result.

6. The system of claim 5, wherein, The verification module is used for comparing the vibration value of the rotor system after the optimized arrangement scheme with the preset vibration threshold value to obtain the final verification result.

7. A simulation verification method of an aero-engine rotor blade arrangement optimization algorithm, characterized in that, The system implementation based on claim 5 or claim 6 comprises: The simulation blade mass is obtained and input into the verification object module to obtain the optimized arrangement scheme; According to the optimized arrangement scheme, the simulation blades are sequentially installed into the holes in the outer edge of the simulation disc by disassembling and assembling the modules, to form the simulation impeller after the arrangement optimization, and the simulation impeller is installed at the end of the output shaft of the driving motor, to form the measured rotor system after the optimization; The transceiver module adjusts the rotating speed of the driving motor according to the received start-stop instruction and rotating speed adjustment instruction of the driving motor; The acquisition module acquires the rotating speed of the simulation impeller after the optimization of the current arrangement scheme and the radial vibration value of the measured rotor system after the optimization; The target comparison information is acquired, and the radial vibration value of the measured rotor system after the optimization is compared with the target comparison information, to verify the optimization effect of the arrangement scheme.

8. The method of claim 7, wherein, The target comparison information is acquired, and the radial vibration value of the measured rotor system after the optimization is compared with the target comparison information, to verify the optimization effect of the arrangement scheme, including: The simulation blades are randomly installed into the holes in the outer edge of the simulation disc, to form the simulation impeller before the arrangement optimization, and the simulation impeller is installed at the end of the output shaft of the driving motor, to form the measured rotor system before the optimization; The acquisition module acquires the rotating speed of the simulation impeller under the current arrangement scheme and the radial vibration value of the measured rotor system before the optimization, and the radial vibration value of the measured rotor system before the optimization is taken as the target comparison information; The verification module compares the target comparison information and the radial vibration value of the measured rotor system after the optimization under different rotating speeds, and if the radial vibration value is smaller than the target comparison information, the verification is passed, and the optimized arrangement scheme is effective.

9. The method of claim 8, wherein, The target comparison information is acquired, and the radial vibration value of the measured rotor system after the optimization is compared with the target comparison information, to verify the optimization effect of the arrangement scheme, including: The vibration threshold value is determined, and the vibration threshold value is taken as the target comparison information; The verification module compares the target comparison information and the radial vibration value of the measured rotor system after the optimization under different rotating speeds, and if the radial vibration value is smaller than the target comparison information, the verification is passed, and the optimized arrangement scheme is effective.

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