High-speed end face sealing test device and test method thereof

Abstract

The invention discloses a high-speed end face sealing testing device and a testing method thereof. The high-speed end face sealing testing device comprises a machine base, a driving system installed on the machine base, a load simulation system, a medium system, a multi-physics field coupling system, a high-precision measuring system and a data collecting and processing system. Meanwhile, the tested sealing element is installed in the testing cavity, a moving ring part of the tested sealing element is connected with an output shaft of the driving system, and a static ring part of the tested sealing element is installed on an end cover of the testing cavity. By integrating the driving system, the load simulation system, the medium system and the multi-physical-field coupling system, extreme working conditions from a steady state to a transient state, from a normal temperature to cryogenic / high temperature and from a single load to multi-field coupling can be simulated, and full-spectrum working conditions of high-end equipment such as an aero-engine and the like are covered.

Description

Technical Field

[0001] This invention relates to the field of rotary mechanical seal technology, specifically to a high-speed end-face seal testing device and its testing method. Background Technology

[0002] High-speed face seals, such as mechanical seals and dry gas seals, are core components of high-end rotating machinery such as aero engines, gas turbines, and centrifugal compressors. Their performance directly determines the reliability, safety, and efficiency of the entire machine. These seals typically operate under extreme conditions such as high temperature, high pressure, high speed, and variable operating conditions, and their failure can lead to catastrophic consequences.

[0003] To verify the reliability of a sealing design, rigorous testing must be conducted before it is put into use. Existing sealing testing equipment, such as test benches that comply with standards like API 682 and ISO 21049, are mainly designed for centrifugal pumps in fields such as petrochemicals. Their test speeds (usually below 10,000 rpm), temperature and pressure ranges, and the complexity of the operating condition simulations are no longer sufficient to meet the stringent sealing performance requirements of cutting-edge fields such as aero-engines.

[0004] Specifically, the existing technology has the following shortcomings: 1. Limited simulation of operating conditions: Existing test benches mainly focus on simulating steady-state operating conditions, making it difficult to reproduce the thermal shock, vibration shock, and complex environment of multi-physics field (mechanical-thermal-chemical) coupling during the start-up and shutdown of aero engines.

[0005] 2. Insufficient testing accuracy and dynamic monitoring capabilities: Traditional measurement methods are difficult to accurately and in real time monitor key parameters such as micron-level dynamic gaps, transient temperature field distribution, and early microcracks on the sealing end face under high-speed rotation.

[0006] 3. Long testing cycle and poor predictability: The testing methods rely heavily on long-term durability tests and lack data-based predictive analysis and failure warning capabilities, making it impossible to quickly evaluate the merits of the design scheme.

[0007] 4. Lack of special environment simulation capabilities: Existing test benches lack effective simulation capabilities for microgravity and vacuum environments in the aerospace field, as well as strong radiation and corrosive environments in nuclear power plants.

[0008] Therefore, there is an urgent need to develop a high-speed end-face seal testing device and method that can comprehensively simulate extreme working conditions, possess high-precision dynamic monitoring capabilities, and perform predictive analysis, in order to meet the research and verification needs of high-performance seals in the high-end equipment field. To this end, we propose a new high-speed end-face seal testing device and its testing method. Summary of the Invention

[0009] The purpose of this invention is to provide a high-speed end face seal testing device and its testing method. This system can simulate extreme working conditions of multi-physics field coupling, realize high-precision dynamic monitoring and predictive analysis of the performance of the seal, and thus comprehensively and efficiently evaluate the reliability of the high-speed end face seal.

[0010] To achieve the above objectives, the present invention provides the following technical solution: a high-speed end-face sealing test device, comprising: Base; The drive system, fixedly mounted on the base, is used to drive the simulated rotor to rotate. The drive system includes a magnetic levitation bearing motor, which can achieve stepless speed regulation from 0 to 30,000 rpm and torque control accuracy of ±0.5%. The load simulation system is used to apply axial force and radial disturbance to the seal under test; A media system for providing a test medium with controllable pressure and temperature to the seal under test; A multiphysics coupling system is used to simultaneously apply vibration loads and thermal shock loads to the tested sealing component; A high-precision measurement system is used to monitor the performance parameters of the tested seal in real time. The high-precision measurement system includes a measurement unit for monitoring leakage, end face temperature field, and dynamic vibration, as well as an online diagnostic unit for monitoring the contact state of the friction pair, the strain distribution of the sealing ring, and the local over-temperature point on the end face. The data acquisition and processing system is electrically connected to the high-precision measurement system and is used to acquire data and analyze it based on machine learning algorithms.

[0011] Preferably, the load simulation system includes: The axial loading module uses a servo hydraulic actuator and can provide dynamic axial force of 0-50kN; The radial floating module enables the stationary or rotating ring of the tested seal to have a radial floating displacement of ±1mm.

[0012] Preferably, the multiphysics coupling system includes: Axial vibration exciter, capable of generating vibrations in the frequency range of 100-2000Hz; The rapid temperature change module can apply a temperature change rate of ≥10℃ / s to the test medium.

[0013] Preferably, the online diagnostic unit includes an acoustic emission sensor, a fiber Bragg grating sensor, and a quantum dot temperature sensor; wherein the acoustic emission sensor can detect microcracks at the 10μm level, the fiber Bragg grating sensor has a strain measurement accuracy of 1μE resolution, and the quantum dot temperature sensor has a spatial resolution of 0.1mm.

[0014] Preferably, it also includes a special environment simulation chamber capable of providing a vacuum environment and / or a three-dimensional micro-vibration environment for testing the seals of the spacecraft propulsion system.

[0015] The present invention also provides a testing method for a high-speed end-face sealing testing device, comprising the following steps: S1: Basic performance test, including static leakage test, running-in test and limit speed test of the tested seal; S2: Enhanced operating condition testing, by increasing the solid content of the medium and increasing the start-stop frequency, accelerates the seal failure process; S3: Multi-physics coupling test, the multi-physics coupling system is started simultaneously to apply axial vibration and thermal shock to the tested seal; S4: Online diagnosis and data fusion analysis. During the test, real-time data is acquired through the high-precision measurement system, and the machine learning algorithm in the data acquisition and processing system is used to extract wavelet packet decomposition features from the vibration signal. An LSTM neural network is then used to establish a life prediction model. S5: Failure Mode Analysis and Improvement: Analyze the failure modes of the tested seal based on the test results and propose corresponding improvement measures; S6: Digital Twin and Intelligent Verification. Establish a digital twin model of the testing process, couple CFD simulation to predict liquid film pressure distribution in real time, and use hardware-in-the-loop technology to quickly verify the improvement scheme.

[0016] Preferably, in step S1: the static leakage test is performed by holding the pressure at 1.1 times the design pressure for 30 minutes, requiring the leakage to be less than 120% of the design value; The running-in test is as follows: the speed is increased from 20% of the rated speed to 100% of the rated speed in steps, and each step is maintained for 30 minutes, requiring the friction coefficient to be stable between 0.05 and 0.15; The extreme speed test is: continuous operation at 1.2 times the rated speed for 2 hours, requiring no plastic deformation of the material.

[0017] Preferably, in step S5: when the failure mode is thermal cracking, the improvement measure is to optimize the cooling channel and adopt a CVD diamond coating; When the failure mode is end face deformation, the improvement measure is to perform deep cryogenic treatment on the sealing ring; When the failure mode is dynamic instability, the improvement measure is to perform laser surface texturing on the sealing end face.

[0018] Preferably, the method further includes the step of: S7: Special environment test. When the test object is a sealed spacecraft, a cryogenic test and / or corrosion test shall be carried out in the special environment simulation chamber.

[0019] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention integrates a drive system, a load simulation system, a medium system, and a multiphysics coupling system to simulate extreme working conditions ranging from steady state to transient state, from room temperature to cryogenic / high temperature, and from single load to multi-field coupling, covering the full spectrum of working conditions for high-end equipment such as aero engines.

[0020] 2. This invention comprehensively utilizes advanced sensing technologies such as Coriolis flowmeters, infrared thermal imagers, laser vibrometers, acoustic emission, and fiber optic gratings to construct a dynamic monitoring system at the μm and μs levels. This system can capture weak signals of early seal failure and achieve in-depth insight from "macroscopic performance" to "microscopic mechanism".

[0021] 3. This invention introduces machine learning and digital twin technologies, elevating testing from "post-event verification" to "pre-event prediction." Through data-driven lifetime models and physical model-driven simulations, the R&D cycle can be significantly shortened, and a data foundation and verification platform can be provided for intelligent sealing (such as active gap control and self-sensing).

[0022] 4. The device design of this invention takes into account the testing needs of ground-based aero-engines and spacecraft propulsion systems. By changing the special environment simulation chamber, it is possible to quickly switch between different application scenarios, which has extremely high application value and promotion prospects. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of a high-speed end-face sealing test device according to the present invention.

[0024] Figure 2 This is a flowchart of the testing method in this invention.

[0025] Legend: 1. Base; 2. Drive system; 3. Load simulation system; 4. Medium system; 5. Multiphysics coupling system; 6. High-precision measurement system; 7. Data acquisition and processing system; 8. Sealing component under test; 9. Test chamber. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] Example 1 Please see Figure 1 - Figure 2This invention provides a high-speed end-face seal testing device, including a base 1, and a drive system 2, a load simulation system 3, a medium system 4, a multi-physics coupling system 5, a high-precision measurement system 6, and a data acquisition and processing system 7 mounted on the base 1. Simultaneously, the seal 8 under test is installed inside a test chamber 9, with its dynamic ring connected to the output shaft of the drive system 2, and its stationary ring mounted on the end cover of the test chamber 9.

[0028] The drive system 2 is fixedly mounted on the base 1 and is used to drive the simulated rotor E to rotate. The drive system 2 uses a magnetic levitation bearing motor, which can achieve stepless speed regulation from 0 to 30,000 rpm and torque control accuracy of ±0.5%. The magnetic levitation bearing eliminates mechanical friction and oil film disturbance, providing a pure dynamic environment for high-precision measurement.

[0029] The load simulation system 3 is used to apply axial force and radial disturbance to the seal under test 8. It includes: an axial loading module, which uses a servo hydraulic actuator with a response frequency of up to 50Hz to apply a precise and controllable axial force to the sealing end face, and can provide a dynamic axial force of 0-50kN; and a radial floating module, which can make the stationary ring or the moving ring of the seal under test generate a radial floating displacement of ±1mm to simulate the radial runout of the rotor shaft.

[0030] The medium system 4 provides a test medium with controllable pressure and temperature for the tested seal 8. It can provide a test medium with a pressure of 0-20 MPa and a temperature of -50 to 400°C, with a flow control accuracy of ±1%. It includes a high-temperature gear pump, a heater, a cooler, and a PID temperature controller. In this embodiment, the lubricating oil medium used in aircraft engines is simulated, with a temperature set at 200°C and a pressure of 5 MPa.

[0031] The multiphysics coupling system 5 is used to simultaneously apply vibration loads and thermal shock loads to the tested seal 8. It includes an axial vibration exciter mounted at the bottom of the test chamber 9 and a rapid temperature change module integrated in the medium pipeline. The axial vibration exciter can generate vibrations of 100-2000Hz to simulate the vibration transmission of an engine casing. The rapid temperature change module achieves a 10℃ / s thermal shock to the seal by instantaneously switching between hot and cold media.

[0032] The high-precision measurement system 6 is used to monitor the performance parameters of the tested seal 8 in real time. The high-precision measurement system 6 includes a Coriolis mass flow meter (accuracy of 0.1%) installed on the leakage pipeline for monitoring leakage, an infrared thermal imager (accuracy of ±1℃) facing the sealing end face for capturing the end face temperature field, a laser vibration meter for non-contact measurement of dynamic vibration, and an online diagnostic unit for monitoring the contact state of the friction pair, the strain distribution of the sealing ring, and the local over-temperature point on the end face. Specifically, the online diagnostic unit includes an acoustic emission sensor mounted on the test chamber 9, a fiber Bragg grating sensor embedded in the sealing ring, and a quantum dot temperature sensor arranged near the sealing end face. These sensors are used to monitor the contact state of the friction pair, the strain distribution of the sealing ring, and local over-temperature points on the end face, respectively. The acoustic emission sensor can detect microcracks at the 10μm level and is used to capture micro-stripping signals of the friction pair. The fiber Bragg grating sensor has a strain measurement accuracy of 1μE resolution and is used to monitor strain caused by thermal stress. The quantum dot temperature sensor has a spatial resolution of 0.1mm and is used to identify local "hot spots".

[0033] The data acquisition and processing system 7 is electrically connected to the high-precision measurement system 6. It is used to acquire and store data and perform feature extraction and failure prediction analysis based on machine learning algorithms. Specifically, it adopts a high-speed data acquisition card and an industrial computer. The built-in software platform can display all parameters in real time and run machine learning algorithms based on Python.

[0034] It also includes a special environment simulation chamber R, capable of providing a vacuum environment with a vacuum level of up to 10. -3 The Pa and three-dimensional micro-vibration environment vibration acceleration are on the order of μg, and are used for testing the seals of spacecraft propulsion systems.

[0035] The testing method using this device is as follows: 1. Basic Performance Testing: First, a static leakage test is conducted at 1.1 times the design pressure, held for 30 minutes, and the leakage amount is recorded. Next, a running-in test is performed, with the speed gradually increased from 20% of the rated speed to 100% in 30-minute increments, monitoring the friction torque until it stabilizes within the 0.05-0.15 range. Finally, a limit speed test at 1.2 times the rated speed (e.g., 36,000 rpm) is conducted for 2 hours, checking for any plastic deformation of the material.

[0036] 2. Enhanced operating condition test: Mix solid particles three times the normal value into the medium and increase the start-stop frequency to 50 times / hour to accelerate wear and fatigue failure.

[0037] 3. Multi-physics coupling test: Under rated operating conditions, the axial vibration exciter (frequency 500Hz, amplitude 10μm) and the rapid temperature change module (from 200℃ to 50℃) are started simultaneously to monitor the transient response and stability of the seal.

[0038] 4. Online diagnosis and data fusion analysis: During the entire test, the acoustic emission signal is decomposed by wavelet packet, and the feature vector representing the microcrack is extracted and input into the LSTM neural network model to predict the remaining service life of the seal in real time.

[0039] 5. Failure Mode Analysis and Improvement: After the test, the seal was disassembled. If thermal cracking was found on the end face, a sealing ring with optimized cooling channels and a CVD diamond coating was used for verification in the next round of testing.

[0040] 6. Digital Twin Testing: During testing, a CFD simulation model synchronized with real-time data from the test bench is run to predict the liquid film pressure and temperature distribution within the sealed gap, and the results are compared and verified with measured data. Using hardware-in-the-loop technology, improved control algorithms (such as piezoelectric ceramic active control) are rapidly validated in the digital model before being applied to actual testing.

[0041] Test chamber 9 can also be replaced with a special environment simulation chamber. First, evacuate the chamber to 10°C. -3 Pa simulates the space environment. Simultaneously, three-dimensional random vibrations at the μg level are applied using a micro-vibration table to simulate spacecraft attitude disturbances. The remaining test procedures are similar to Example 1, focusing on evaluating the leakage rate of the seal under microgravity and vacuum conditions and the material's gas escape performance.

[0042] Example 2 The present invention also provides a testing method for a high-speed end-face sealing testing device, comprising the following steps: S1: Basic performance test, static leakage test, running-in test and limit speed test are performed on the tested seal 8; The static leakage test involves holding the pressure at 1.1 times the design pressure for 30 minutes, requiring the leakage to be less than 120% of the design value. The running-in test is as follows: the speed is increased from 20% of the rated speed to 100% of the rated speed in steps, and each step is maintained for 30 minutes. The friction coefficient is required to be stable between 0.05 and 0.15. The extreme speed test is: continuous operation at 1.2 times the rated speed for 2 hours, requiring no plastic deformation of the material; S2: Enhanced operating condition testing, by increasing the solid content of the medium and increasing the start-stop frequency, accelerates the seal failure process; S3: Multi-physics coupling test, synchronously start the multi-physics coupling system 5, apply axial vibration and thermal shock to the tested seal 8, simulate the transient response under actual working conditions; S4: Online diagnosis and data fusion analysis. During the test, real-time data is acquired through the high-precision measurement system 6, and the machine learning algorithm in the data acquisition and processing system 7 is used to extract the wavelet packet decomposition features of the vibration signal. An LSTM neural network is then used to establish a life prediction model. S5: Failure Mode Analysis and Improvement. Based on the test results, analyze the failure modes of the tested seal 8 and propose corresponding improvement measures. When the failure mode is thermal cracking, the improvement measures are to optimize the cooling channel and adopt CVD diamond coating. When the failure mode is end face deformation, the improvement measure is to perform deep cryogenic treatment on the sealing ring; When the failure mode is dynamic instability, the improvement measure is to perform laser surface texturing on the sealing end face; S6: Digital Twin and Intelligent Verification. Establish a digital twin model of the testing process, couple CFD simulation to predict liquid film pressure distribution in real time, and use hardware-in-the-loop technology to quickly verify the improvement scheme.

[0043] S7: Special environment test. When the test object is a sealed spacecraft, a cryogenic test in a liquid nitrogen environment and a corrosion test in a H2S+CO2 mixed gas are conducted in a special environment simulation cabin R.

[0044] Application Example 1 To verify the effectiveness of the device of the present invention, a dry gas seal for the main shaft of a certain type of aero-engine was selected as the seal to be tested 8, with a design speed of 25,000 rpm and a design pressure of 6 MPa.

[0045] 1. Basic performance test data analysis: Static leakage test: After holding at 6.6 MPa (1.1 times the design pressure) for 30 minutes, the Coriolis mass flow meter measured an average leakage rate of 0.85 ml / min, which is 120% lower than the design value (1.0 ml / min) (i.e., 1.2 ml / min), meeting the qualification standard. This indicates that the seal has good closure performance under static conditions.

[0046] Running-in test: The engine speed was gradually increased from 5,000 rpm to 25,000 rpm, with each increment maintained for 30 minutes. Data showed that the friction torque gradually decreased from the initial 0.25 N·m and stabilized at 0.12 N·m, corresponding to a stable friction coefficient of 0.08, within the ideal range of 0.05-0.15. Infrared thermal imaging showed that after the running-in period, the average end-face temperature stabilized at 95℃, with uniform temperature distribution and no localized hot spots.

[0047] Ultimate speed test: The device operated continuously for 2 hours at 30,000 rpm (1.2 times the rated speed). The axial vibration amplitude of the sealing end face, measured by a laser vibrometer, remained below 3 μm, indicating stable operation. After the test, flaw detection of the sealing ring revealed no plastic deformation or cracks, proving that its structural strength meets the requirements of the ultimate operating conditions.

[0048] 2. Enhanced working conditions and multiphysics coupling test analysis: Enhanced operating condition testing: The medium was supplemented with 3 times the solids content, and the start-stop frequency was increased to 50 times / hour. After 50 hours of continuous testing, the leakage rate began to rise slowly. The acoustic emission sensors of the online diagnostic system detected a significant increase in the energy and frequency of impact events. Wavelet packet decomposition results showed that the proportion of high-frequency energy increased by 15%, and the LSTM neural network model issued an early warning based on this, predicting a remaining lifetime of approximately 20 hours.

[0049] Multiphysics coupling test: Under conditions of 20,000 rpm and 5 MPa, axial vibration of 500 Hz and 10 μm and thermal shock of 10℃ / s (from 150℃ to 50℃) were simultaneously applied. The quantum dot temperature sensor array captured the instant of thermal shock, and a 0.2 mm increase appeared in a certain area of ​​the end face. 2 The device reached its instantaneous overheating point, with the temperature soaring to 180°C (85°C higher than the average temperature), but recovered rapidly within one second. Fiber Bragg grating data showed an instantaneous tensile strain of 120 μE in this region. This demonstrates the device's ability to accurately capture extreme transient conditions, a crucial data point that traditional testing methods cannot obtain.

[0050] 3. Failure Mode Analysis and Improvement Validation: Failure Analysis: After operation under stressed conditions until failure, disassembly revealed significant thermal cracking on the sealing end face. Comparison with online diagnostic data confirmed abnormal peak values ​​in both the acoustic emission signal and local over-temperature points prior to failure, validating the effectiveness of the diagnostic system. The cause was determined to be that localized thermal stress under transient conditions exceeded the tensile strength of the material (silicon carbide).

[0051] Improvement Verification: An improved seal with optimized internal cooling channels and a 2μm thick CVD diamond coating was used and retested under the same operating conditions. Results showed that the peak instantaneous overtemperature detected by the quantum dot temperature sensor decreased by 40℃, and the instantaneous strain measured by the fiber Bragg grating decreased by 30%. The improved seal exhibited a 3-fold increase in lifespan under enhanced operating conditions, validating the effectiveness of the improvements.

[0052] 4. Digital Twin and Intelligent Verification Analysis: Digital twin model: The liquid film pressure distribution predicted by real-time CFD simulation is highly consistent with the pressure distribution obtained by back-calculation through the strain of the sealing ring, with an error of less than 5%. The digital twin model successfully predicted that the liquid film would become unstable at a specific vibration frequency, and this prediction is consistent with the sudden increase in vibration amplitude observed in actual tests.

[0053] Hardware-in-the-loop (HIL) verification: To address the liquid film instability problem, an active gap control algorithm based on piezoelectric ceramics was developed. The algorithm first undergoes rapid iterative optimization using HIL in a digital twin model, and then the optimized control parameters are downloaded to the piezoelectric ceramic actuator on the test bench. Experimental data shows that this active control system can respond and suppress liquid film instability within 0.8 ms, reducing vibration amplitude by 60%, thus achieving "intelligent sealing testing."

[0054] Performance analysis conclusion: This embodiment fully demonstrates that the device of the present invention can not only complete traditional tests, but also reproduce extreme transient conditions. Through a high-precision measurement system and intelligent analysis platform, it can deeply reveal the microscopic mechanism of seal failure, achieving a leap from "testing" to "prediction and optimization".

[0055] Application Example 2 To verify the application capability of this device in the aerospace field, a bellows seal of a certain type of satellite attitude control and propulsion system was selected as the test component, with an on-orbit working pressure of 2MPa.

[0056] 1. Environmental simulation and static performance analysis: Environmental simulation: The special environment simulation chamber successfully evacuated the vacuum level to 8x10. -4 Pa was applied, and triaxial random vibrations were applied with a total root mean square acceleration of 2 μg to simulate the on-orbit micro-vibration environment.

[0057] Static leakage test: The pressure was maintained for 30 minutes under vacuum and 2.2 MPa (1.1 times the design pressure) helium medium. The leakage rate measured by the Coriolis mass flow meter was 1.2 x 10⁻⁶. -6 Pa·m 3 / s, better than the design specifications (5x10 -6 Pa·m 3 The value is on the order of magnitude ( / s), indicating that the seal has excellent sealing performance in a vacuum environment.

[0058] 2. On-orbit operating condition simulation and dynamic performance analysis: Thermal cycling test: Simulating satellite entry and exit from Earth's shadow, the sealing components were subjected to high and low temperature cycling from -100℃ to +100℃ for 90 minutes. During the cycling process, the leakage rate remained stable. Fiber optic Bragg grating data showed that the strain changes of the bellows and sealing ring exhibited a good linear relationship with temperature changes, without hysteresis or anomalies, indicating that the material did not undergo a brittle transition in the cryogenic region.

[0059] Stability testing under micro-vibration: Under the combined effects of vacuum, 2MPa pressure, and μg-level micro-vibration, the relative vibration amplitude of the sealed end face measured by the laser vibrometer was less than 0.5μm. This indicates that the seal is insensitive to micro-vibration of the spacecraft platform and will not fail prematurely due to fretting wear.

[0060] 3. Monitoring of material gas emission performance (additional analysis): The special environment simulation chamber of this device can be used in conjunction with a residual gas analyzer (RGA). Under vacuum and high temperature (+100°C) conditions, the RGA monitored a total mass loss of 0.08% and a collectable condensate volatile content of 0.01% for the sealing material (special fluororubber), both of which meet the spacecraft material selection standards (TML<1.0%, CVCM<0.1%), verifying the space suitability of the sealing material.

[0061] Performance analysis conclusion: This embodiment proves that the device of the present invention, by integrating a special environment simulation chamber, can effectively and accurately assess the comprehensive performance of sealing components under extreme aerospace environments such as vacuum, cryogenics, and micro-vibration, including sealing performance, structural stability, material adaptability, and even gas venting performance, providing an indispensable ground verification method for the reliability and long-life design of spacecraft.

[0062] In summary, this invention proposes a high-speed end-face sealing test device and test method, and mainly solves the following problems: 1. Traditional sealing test devices can usually only simulate a single or a few steady-state conditions, which are far from the complex conditions of the entire process of "start-up-operation-load change-shutdown" experienced by equipment such as aero engines and spacecraft in actual operation. This results in a huge deviation between the test results and the actual service performance, i.e., "inaccurate measurement".

[0063] This invention, through the deep integration of a drive system, load simulation system, media system, and multiphysics coupling system, constructs a "simulator" capable of comprehensively reproducing extreme service environments. It can simulate ultra-high speeds up to 30,000 rpm, a wide temperature range from -50℃ to 400℃, and high pressures of 20MPa. More importantly, it can simultaneously apply high-frequency vibrations (100-2000Hz) and rapid thermal shocks (≥10℃ / s). This multiphysics dynamic coupling simulation capability can accurately reproduce the impact of key transient processes such as engine surge, afterburner ignition, and attitude adjustment on the seals, improving the fidelity of test conditions to actual operating conditions by several orders of magnitude. Therefore, the test data obtained through this device can truly reflect the performance and life limits of seals in actual equipment, fundamentally solving the industry pain point of "inaccurate measurement."

[0064] 2. Existing testing methods mostly rely on offline or quasi-online measurement of macroscopic parameters such as leakage rate and torque. They have extremely weak ability to detect early microscopic signals of sealing failure (such as microcrack initiation, local temperature rise, and strain concentration), and problems are often only discovered after catastrophic failure has occurred.

[0065] This invention creatively constructs a cross-scale, multi-information fusion in-situ dynamic monitoring system. This system not only includes high-precision macroscopic measurement units (Coriolis flowmeter, infrared thermal imager) but also integrates cutting-edge online diagnostic units. Acoustic emission technology can capture stress wave signals released during micron-level spalling and crack propagation of friction pairs, enabling "audible" perception of early damage. Fiber Bragg gratings, like a "neural network" implanted in the sealing ring, can monitor μm-level strain distribution in real time, revealing the coupling effect of thermal and mechanical stress. Quantum dot thermometry provides unprecedented "visual" capabilities, capturing instantaneous overheating points in the micron-level region of the end face with a spatial resolution of 0.1 mm, precisely locating the source of thermal failure. This system allows researchers to, for the first time, "see" and "hear" the microscopic changes inside the seal in real time under extreme environments of high-speed rotation, high temperature, and high pressure. It pushes seal research from "black box" macroscopic performance testing to "transparent" microscopic mechanism exploration, providing unprecedented data support for seal design and failure analysis.

[0066] 3. Traditional testing methods rely on long-term durability tests to obtain lifespan data, which has a long development cycle, high cost, and cannot predict the remaining lifespan of individual seals.

[0067] This invention achieves a revolutionary upgrade to the testing mode through machine learning algorithms built into the data acquisition and processing system: First, by extracting features from multi-source signals such as acoustic emission and vibration through wavelet packet decomposition, and utilizing deep learning models such as LSTM, a high-precision life prediction model can be established. This model can assess the health status of the seal in real time during testing, predict its remaining useful life, and provide a basis for decision-making for condition-based maintenance and predictive maintenance.

[0068] Secondly, this device is not only a physical testing platform but also a physical carrier of a digital twin system. Through real-time coupled CFD simulation, it can predict the pressure distribution of the liquid film between end faces, which is invisible to the human eye. More importantly, HIL technology allows new control algorithms (such as piezoelectric ceramic active gap control) or improved sealing structure models to be rapidly and cost-effectively iteratively verified in digital space first. After successful verification, they can be deployed to the physical testing bench, greatly accelerating the research and verification process of "intelligent sealing" technology. This dual-drive mode of "data-driven + physical model" elevates sealing testing from passive "post-verification" to proactive "pre-prediction and optimization," representing a huge leap in research and development concepts and efficiency.

[0069] 4. Existing test benches are often designed for specific industries (such as petrochemicals) and are powerless to meet the special needs of fields such as aviation and aerospace (such as vacuum, microgravity, cryogenics, and strong corrosion).

[0070] The modular design of this invention allows the core testing unit to seamlessly interface with different environmental simulation chambers. For example, by replacing a special environmental simulation chamber, high-temperature and high-speed testing of the main seal of an aero-engine, as well as performance evaluation of the spacecraft propulsion system seal under vacuum, cryogenic, and micro-vibration environments, can be completed on the same equipment. This "one machine, multiple uses" capability not only significantly reduces the repetitive investment costs of high-end testing equipment, but also provides a unified, advanced, and strategically significant testing and verification platform for my country's independent research and development of key core components in different fields such as aerospace, navigation, and energy.

[0071] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A high-speed end-face sealing test device, characterized in that, include: Base (1); The drive system (2) is fixedly mounted on the base (1) and is used to drive the simulated rotor (E) to rotate. The drive system (2) includes a magnetic levitation bearing motor, which can achieve stepless speed regulation from 0 to 30,000 rpm and torque control accuracy of ±0.5%. The load simulation system (3) is used to apply axial force and radial disturbance to the seal under test (8); The medium system (4) is used to provide a test medium with controllable pressure and temperature for the seal under test (8); A multi-physics coupling system (5) is used to simultaneously apply vibration load and thermal shock load to the tested seal (8); A high-precision measurement system (6) is used to monitor the performance parameters of the tested seal (8) in real time. The high-precision measurement system (6) includes a measurement unit for monitoring leakage, end face temperature field, and dynamic vibration, as well as an online diagnostic unit for monitoring the contact state of the friction pair, the strain distribution of the sealing ring, and the local over-temperature point on the end face. The data acquisition and processing system (7) is electrically connected to the high-precision measurement system (6) and is used to acquire data and analyze it based on machine learning algorithms.

2. The high-speed end-face sealing test device according to claim 1, characterized in that, The load simulation system (3) includes: The axial loading module uses a servo hydraulic actuator and can provide dynamic axial force of 0-50kN; The radial floating module enables the stationary or moving ring of the tested seal (8) to have a radial floating displacement of ±1mm.

3. The high-speed end-face sealing test device according to claim 1, characterized in that, The multiphysics coupling system (5) includes: Axial vibration exciter, capable of generating vibrations in the frequency range of 100-2000Hz; The rapid temperature change module can apply a temperature change rate of ≥10℃ / s to the test medium.

4. The high-speed end-face sealing test device according to claim 1, characterized in that, The online diagnostic unit includes an acoustic emission sensor, a fiber Bragg grating sensor, and a quantum dot temperature sensor; wherein, the acoustic emission sensor can detect microcracks at the 10μm level, the fiber Bragg grating sensor has a strain measurement accuracy of 1μE resolution, and the quantum dot temperature sensor has a spatial resolution of 0.1mm.

5. The high-speed end-face sealing test device according to claim 1, characterized in that, It also includes a special environment simulation chamber that can provide a vacuum environment and a three-dimensional micro-vibration environment for testing the seals of spacecraft propulsion systems.

6. The test method of the high-speed end-face sealing test device according to any one of claims 1-5, characterized in that, Includes the following steps: S1: Basic performance test, static leakage test, running-in test and limit speed test are performed on the tested seal (8); S2: Enhanced operating condition testing, by increasing the solid content of the medium and increasing the start-stop frequency, accelerates the seal failure process; S3: Multi-physics coupling test, the multi-physics coupling system (5) is started simultaneously to apply axial vibration and thermal shock to the tested seal (8); S4: Online diagnosis and data fusion analysis. During the test, real-time data is acquired through the high-precision measurement system (6), and the machine learning algorithm in the data acquisition and processing system (7) is used to extract the wavelet packet decomposition features of the vibration signal. An LSTM neural network is used to establish a life prediction model. S5: Failure Mode Analysis and Improvement. Based on the test results, analyze the failure modes of the tested seal (8) and propose corresponding improvement measures. S6: Digital Twin and Intelligent Verification. Establish a digital twin model of the testing process, couple CFD simulation to predict liquid film pressure distribution in real time, and use hardware-in-the-loop technology to quickly verify the improvement scheme.

7. The test method of the high-speed end-face sealing test device according to claim 6, characterized in that, In step S1: the static leakage test is performed by holding the pressure at 1.1 times the design pressure for 30 minutes, requiring the leakage to be less than 120% of the design value; The running-in test is as follows: the speed is increased from 20% of the rated speed to 100% of the rated speed in steps, and each step is maintained for 30 minutes, requiring the friction coefficient to be stable between 0.05 and 0.15; The extreme speed test is: continuous operation at 1.2 times the rated speed for 2 hours, requiring no plastic deformation of the material.

8. The test method of the high-speed end-face sealing test device according to claim 6, characterized in that, In step S5: when the failure mode is thermal cracking, the improvement measures are to optimize the cooling channels and adopt CVD diamond coating; When the failure mode is end face deformation, the improvement measure is to perform deep cryogenic treatment on the sealing ring; When the failure mode is dynamic instability, the improvement measure is to perform laser surface texturing on the sealing end face.

9. The test method of the high-speed end-face sealing test device according to claim 6, characterized in that, It also includes the following steps: S7: Special environment test. When the test object is a sealed spacecraft, a cryogenic test and / or corrosion test shall be carried out in the special environment simulation chamber.

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