High-integration multifunctional ground tester lubricating system and working method thereof

Abstract

The invention discloses a high-integration multifunctional ground tester lubricating system and a working method thereof, and belongs to the technical field of aero-engine accessory transmission system ground tests. The system takes a lubricating oil tank as a core, and integrates three core function flow paths by optimizing the layout of pipelines and valves: a self-circulation filtering flow path, and offline efficient purification of lubricating oil is realized by utilizing a circulating pump and a series multi-stage oil filter; a product oil supply and cleanliness monitoring flow path can flexibly switch and monitor the cleanliness of lubricating oil at an inlet and an outlet of a product in real time on the premise of not interrupting a test through an oil supply pump, a controllable multi-way valve group and an online particle counter; and the self-circulation heating flow path is matched with the constant temperature machine through the circulating pump, so that uniform and controllable preheating of the lubricating oil is realized. The three flow paths share a core power source (a circulating pump set) and an oil tank, mode selection is carried out through a central switching valve, and high integration of functions and optimal configuration of resources are achieved. The problems that a traditional test lubrication system is single in function, inconvenient in cleanliness monitoring and low in heating efficiency are solved, the test preparation efficiency, the process monitoring capability and the result reliability are remarkably improved, and a key guarantee is provided for a high-standard aviation transmission accessory test.

Description

Technical Field

[0001] This invention relates to the field of ground simulation testing technology for aero-engines and their transmission accessories (such as gearboxes, bearings, etc.), and specifically to a highly integrated ground tester lubrication system that provides lubrication for such tests and integrates lubricant cleanliness control, online monitoring and temperature management functions. Background Technology

[0002] Aircraft transmission accessories (hereinafter referred to as "test products") must undergo rigorous ground simulation tests before installation to verify their performance, durability, and reliability under real-world operating conditions. The lubrication system is a critical subsystem of such test benches, and its performance directly affects the effectiveness and safety of the test. Traditional ground testing equipment lubrication systems have the following prominent drawbacks:

[0003] 1. Limited functionality and passive cleanliness control: Typically, it only has basic "oil supply-return" functions, with filtration mainly relying on individual oil filters in the product's inlet and return oil lines. This design cannot actively and deeply purify the contaminated lubricating oil in the tank when the product is not in operation (during test intervals). If the lubricating oil cleanliness does not meet the standards before the test, it will directly lead to distorted test data and even premature product wear.

[0004] 2. Offline and inconvenient cleanliness monitoring: When monitoring the cleanliness of lubricating oil is required, the machine must be stopped, samples must be manually taken from the pipeline, and then sent to an offline laboratory for analysis using a particle counter. This process is time-consuming, prone to secondary contamination, and cannot obtain real-time, continuous cleanliness data, making it difficult to detect abnormal phenomena such as a surge in particulate matter caused by product wear during the test.

[0005] 3. Inefficient and risky heating methods: Common heating methods include installing rod heaters on the oil supply line or heating the bottom of the oil tank. This method easily leads to localized overheating of the lubricating oil, resulting in carbon buildup, and also has low heating efficiency and poor uniformity. Starting the product in low-temperature lubricating oil or running it for too long may pose testing risks due to high viscosity and poor lubrication.

[0006] 4. System redundancy and low integration: To meet different functions, multiple independent pump sets, valves and pipelines are often used, resulting in complex systems, large footprints, high costs, and poor coordination between functions.

[0007] Therefore, developing a highly integrated and easy-to-operate ground tester lubrication system that combines high-efficiency filtration, online monitoring, and intelligent temperature control has become an urgent need to improve the quality and efficiency of aerospace transmission accessory testing. Summary of the Invention

[0008] The purpose of this invention is to overcome the shortcomings of existing ground testing equipment lubrication systems and provide a highly integrated, multifunctional ground testing equipment lubrication system. This system aims to achieve the following objectives: 1. Achieve active and deep purification of lubricating oil: During non-working periods, the product can perform closed-loop circulation filtration of all lubricating oil in the tank, significantly improving and maintaining the cleanliness level of the lubricating oil.

[0009] 2. Enables online and flexible monitoring of lubricating oil cleanliness: During test runs, the lubricating oil cleanliness of the supplied products can be monitored in real time and in situ without stopping the machine for sampling. It can also be flexibly switched to monitor the cleanliness of the return oil after the products have been used, and comparative analysis can be performed.

[0010] 3. Achieve efficient, uniform, and safe heating of lubricating oil: Adopt a high-flow-rate circulating heat exchange method to avoid local overheating and quickly and uniformly heat the lubricating oil to the set temperature.

[0011] 4. Achieve high system integration and intelligent control: By optimizing flow path design and sharing core components, the three major functions are achieved with minimal hardware configuration, and remote, one-click switching and collaborative management of functions are realized through electric valves and control systems.

[0012] To achieve the above objectives, the core design concept of this invention is to construct three functional flow paths with shared resources and clear logic, using a lubricating oil tank as the oil storage and circulation center, and to achieve overall control through a central switching valve.

[0013] In a first aspect, the present invention provides a highly integrated and multifunctional lubrication system for a ground testing instrument, characterized in that it comprises: 1. Core storage and transportation unit – Lubricating oil tank: Serves as the center for lubricating oil storage, gas separation, and temperature balance within the system. Its volume is typically determined based on the actual oil requirements of the test product or the oil tank volume of the simulated object (such as an engine) to ensure the authenticity of the test conditions.

[0014] 2. Self-circulating filtration path: This path is the system's "purification module." Its power source is the circulating pump set. When lubricating oil purification is required, the circulating pump set is started, and the filter-heating switching valve is operated to direct the lubricating oil from the pump outlet to a multi-stage series filtration branch. This branch includes at least two stages of filters: for example, a first-stage 25μm oil filter for coarse filtration, and a second-stage 10μm and 5μm oil filters for fine filtration (which can be in series or a parallel-series combination). The clean lubricating oil after deep filtration flows back to the lubricating oil tank, forming a closed loop that can continue operating until the lubricating oil cleanliness meets the standards. This function can operate independently before, after, or during any interval.

[0015] 3. Self-circulating heating flow path: This flow path is the system's "temperature control module." It shares the circulating pump set as its power source with the filtration flow path. By operating the filtration-heating switching valve, the lubricating oil at the pump outlet is switched to the heating flow path. The lubricating oil first passes through a heated oil filter (to prevent impurities from damaging downstream equipment) and then enters the thermostat. The thermostat is a high-precision fluid temperature control device (such as an oil bath or plate heat exchanger) that precisely and uniformly heats the circulating lubricating oil using an external heat source (electricity, steam, or heat transfer oil). The heated lubricating oil returns to the oil tank, where it circulates and exchanges heat throughout the entire tank volume, achieving rapid and uniform temperature rise. This function can also be operated when the product is not in operation for test preheating.

[0016] 4. Product Oil Supply and Cleanliness Monitoring Flow Path: This flow path is the "core operating and monitoring module" of the system. Its power source is an independent oil supply pump unit. After the lubricating oil is drawn from the oil tank by the oil supply pump unit, it passes through the inlet oil filter for final accuracy assurance, and then enters the main oil supply pipeline. This pipeline is equipped with an overflow valve to stabilize system pressure and flow, and a turbine flow meter, pressure transmitter, and temperature sensor to monitor oil supply parameters. A radiator is integrated into the pipeline to cool the lubricating oil when needed, working in conjunction with the heating flow path to achieve precise control of the oil supply temperature.

[0017] The core of online cleanliness monitoring lies in a cleanliness data collector (with a built-in high-temperature online particle counter) and a controllable multi-way valve assembly. The valve assembly includes an inlet electric three-way valve and a return electric three-way valve. By controlling these two valves through a program, the operating mode of the data collector can be flexibly configured. Mode 1 (Monitoring Inlet Oil Cleanliness): The inlet electric three-way valve diverts a small stream of oil from the main supply line to the collector inlet, and the return electric three-way valve returns the collector outlet to the main supply line (before the product inlet). At this time, the cleanliness of the lubricating oil that is about to enter the product is being monitored.

[0018] Mode 2 (Monitoring Return Oil Cleanliness): The inlet electric three-way valve directs a stream of oil from the product's return oil line to the inlet of the data collector, while the return electric three-way valve directs the data collector outlet to the return oil tank line. This mode monitors the cleanliness of the lubricating oil after the product has finished operating and is about to return to the oil tank.

[0019] This design allows for the switching measurement and comparison of inlet and return oil cleanliness using only a single online data acquisition unit. A check valve is installed at the end of the flow path to prevent backflow of lubricating oil when the machine is stopped, and the oil flows back to the oil tank after passing through the return oil filter.

[0020] 5. Integrated Control System: All electric valves (filter heating switching valve, oil inlet / return electric three-way valve), pump sets, thermostat, radiator, and various sensors are connected to the central controller. The controller runs dedicated software, which can realize automated functions such as "one-click purification", "one-click preheating", "automatic cleanliness inspection and recording", and "temperature control closed-loop adjustment", and has over-limit alarm capability.

[0021] Secondly, the present invention provides a method for conducting ground tests using the above-described lubrication system, characterized by comprising the following steps: Pre-test preparation stage: Start the circulating pump group, and purify the lubricating oil in the oil tank by operating the flow path switching valve to allow the lubricating oil to flow through the self-circulating filter flow path; and / or, allow the lubricating oil to flow through the self-circulating heating flow path to heat the lubricating oil to the preset test start temperature; Test operation and monitoring phase: Start the oil supply pump group to supply lubricating oil to the test product; by operating the controllable multi-way valve group, connect the cleanliness collector in parallel to the product oil inlet pipeline to monitor the supply cleanliness; then, or as needed, switch the cleanliness collector to connect in parallel to the product oil return pipeline to monitor the return oil cleanliness and compare it with the inlet oil cleanliness. Post-test maintenance phase: After the test, the self-circulating filter flow path is restarted to filter and purify the lubricating oil after use, in preparation for the next test.

[0022] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. Comprehensive and highly integrated functions: It organically integrates three advanced functions—filtration, heating, and online monitoring—into a compact system, sharing oil tanks, pump sets (partially), and control resources, which greatly reduces the number of equipment, floor space, and complexity.

[0023] 2. Proactive lubricating oil quality management: Through the independent "self-circulating filtration" function, the lubricating oil can be "maintained" at any time, ensuring that each test starts with high-cleanliness lubricating oil, thus guaranteeing the quality of the test from the source.

[0024] 3. Revolutionary process monitoring capabilities: Online cleanliness monitoring represents a leap from "post-testing" to "real-time process monitoring." It can instantly detect abnormal product wear (manifested as a sharp increase in the number of return oil particles), providing unprecedented real-time data support for test safety and fault diagnosis.

[0025] 4. Safe and efficient temperature control solution: Circulating heating avoids the risks of local overheating and carbon buildup, and the heating speed is fast and the temperature is uniform, which significantly shortens the test preparation time and reduces the risk of cold start.

[0026] 5. Flexible configuration and high cost-effectiveness: Using a single data acquisition unit in conjunction with an electric three-way valve achieves bidirectional monitoring, which is more cost-effective than configuring two data acquisition units and offers flexible switching. The system has a high degree of modularity, making it easy to customize and promote according to different experimental needs.

[0027] 6. Intelligent and automated: Centralized control simplifies the operation process, reduces human error, and improves the automation level and operational reliability of the entire test bench.

[0028] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the principle and component layout of a highly integrated and multifunctional ground testing instrument lubrication system in an embodiment of the present invention.

[0030] Explanation of the reference numerals in the figure: 1-Radiator; 2-Pressure transmitter; 3-Turbine flow meter; 4-Data collector; 5-Overflow valve; 6-Inlet oil filter; 7-Oil supply pump set; 8-Lubricating oil tank; 9-Thermostat; 10-Circulating pump set; 11-Heated oil filter; 12-Filter heating switching valve; 13-Temperature sensor; 14-Inlet electric three-way valve; 15-Return electric three-way valve; 16-Check valve; 17-Return oil filter; 18-5μm oil filter; 19-10μm oil filter; 20-25μm oil filter. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The described embodiments are some embodiments of this invention, but not all embodiments.

[0032] The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the invention, and should not be construed as limiting the invention.

[0033] Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of this invention.

[0034] The following is in conjunction with the appendix Figure 1 The embodiments of the present invention will be described in detail below.

[0035] Example 1 This embodiment uses a lubrication system for durability testing of an aircraft gearbox as an example.

[0036] like Figure 1 As shown, all components of the system are organically connected through pipelines, forming a closed-loop system centered on the lubricating oil tank 8. The lubricating oil tank 8 has a capacity of 500 liters, simulating the working conditions of a real engine oil tank, and is equipped with a level gauge, air filter, and drain valve.

[0037] I. Specific Implementation and Interaction of Each Functional Flow Path 1. Self-circulating filtration path (purification mode) When the controller receives the "oil purification" command: Start the circulating pump unit 10 (a gear pump driven by a variable frequency motor).

[0038] Control the filter heating switching valve 12 (one-position three-way electric ball valve) to switch to the "filter" position. At this time, the lubricating oil at the outlet of pump 10 flows to the filter branch.

[0039] The lubricating oil flows sequentially through a 25μm oil filter 20 (coarse filter, intercepting larger particles), a 10μm oil filter 19 (medium-fine filter), and a 5μm oil filter 18 (fine filter). This series arrangement of "coarse first, then fine" protects the fine filter from rapid clogging and achieves efficient removal of particles larger than 5μm, with the goal of raising the lubricating oil cleanliness to at least NAS 6 level.

[0040] The filtered clean lubricating oil is returned directly to the lubricating oil tank 8. This cycle can continue for several hours until online monitoring (via the collector 4 described later, temporarily connected to this flow path or via the oil tank sampling port) shows that the cleanliness meets the standard, or stops according to a preset time.

[0041] 2. Self-circulating heating flow path (preheating mode) When it is necessary to heat the lubricating oil (e.g., when the lubricating oil temperature is required to be 70°C before a test): Start the circulating pump unit 10.

[0042] The filter heating switching valve 12 is switched to the "heating" position. Lubricating oil is pumped into the heating flow path.

[0043] The lubricating oil first passes through a heated oil filter 11 (with an optional precision of 25μm) to protect the subsequent thermostat 9.

[0044] The lubricating oil then enters the temperature control unit 9. In this embodiment, the temperature control unit 9 is an electrically heated oil temperature controller, with built-in heating elements, a plate heat exchanger (with cooling water), and a PID temperature control system. The lubricating oil is rapidly and accurately heated to the set temperature within the temperature control unit 9.

[0045] The heated lubricating oil flows back to the lubricating oil tank 8. The high-flow-rate circulation causes the lubricating oil temperature in the tank to rise rapidly and evenly. Temperature sensor 13 (installed at the inlet of the oil supply pump group 7 or in the oil tank) provides temperature feedback, forming a closed-loop control.

[0046] 3. Product oil supply and cleanliness monitoring flow path (operating and monitoring modes) This flow path is the main pathway during the test run.

[0047] Oil Supply and Temperature Control: The oil supply pump unit 7 (another variable frequency pump) is started, and lubricating oil is drawn from the oil tank 8, passing through the inlet oil filter 6 (3μm absolute accuracy) to ensure extremely high cleanliness of the lubricating oil entering the product. The overflow valve 5 sets the system pressure (e.g., 0.8MPa), and excess oil returns to the oil tank. The turbine flow meter 3 and pressure transmitter 2 monitor the oil supply flow and pressure in real time. The radiator 1 (water-cooled plate heat exchanger) is installed on the pipeline. When the oil supply temperature exceeds the set upper limit, cooling water is introduced to cool it down, working together with the heating function of the constant temperature unit 9 to achieve precise control of the oil supply temperature (e.g., maintaining 70±2℃). The temperature sensor 13 provides feedback on the oil supply temperature.

[0048] Flexible implementation of online cleanliness monitoring: This is the innovative highlight of this system.

[0049] Monitoring Inlet Oil Cleanliness (Mode A): This mode is executed periodically or continuously during the test. Controller Action: The A port of the inlet electric three-way valve 14 is connected to the P port (A→P), diverting approximately 1-2 L / min of lubricating oil from the main oil supply line; the B port of the return electric three-way valve 15 is connected to the T port (B→T). The diverted oil sample enters the collector 4 via valve 14. The collector 4 contains an online laser particle counter, capable of counting and classifying the number of particles of different sizes (4μm, 6μm, 14μm, etc.) in the oil in real time, calculating the ISO or NAS cleanliness level, and uploading it to the control room via 4-20mA or network signal. After testing, the oil sample flows back into the main oil supply line via valve 15, flowing to the test product. This mode verifies whether the lubricating oil supplied to the product is consistently clean.

[0050] Monitoring Return Oil Cleanliness (Mode B): Switch to this mode when it is necessary to check the internal wear condition of the product. Controller Action: The inlet electric three-way valve 14 switches to connect port C and port P (C→P) to take a sample from the product's return oil line; the return oil electric three-way valve 15 switches to connect port D and port T (D→T). At this time, the collector 4 detects the lubricating oil containing wear products after the product has been in operation. The detected oil sample flows directly back to the return oil line before the oil tank via valve 15. This mode can directly reflect the internal working state of the product. If the number of particles suddenly increases sharply, it may indicate abnormal wear.

[0051] The two modes can be automatically switched at regular intervals by the program to achieve automatic comparison and analysis of the cleanliness of the incoming and outgoing oil, automatic data recording, and triggering an alarm when the particle count exceeds the standard.

[0052] Oil return and protection: The return oil from the product passes through the check valve 16 (to prevent backflow of oil when the pump stops), and then through the return oil filter 17 (10μm, mainly to intercept large wear particles) before flowing back to the lubricating oil tank 8, completing the entire working cycle.

[0053] II. System Workflow Example (One Complete Test Cycle) Preparation before the experiment (overnight): Perform "self-circulation filtration" for 4-6 hours to purify the lubricating oil.

[0054] Perform "self-circulation heating" for 2 hours to heat the lubricating oil from room temperature to 70°C.

[0055] Experiment start-up and operation: Start the "Product Oil Supply" flow path and confirm that the flow rate, pressure, and temperature are normal.

[0056] Start the test product.

[0057] The control system automatically executes a "cleanliness monitoring cycle" every 30 minutes: first, it runs mode A (oil inlet monitoring) for 5 minutes and records the data; then it switches to mode B (oil return monitoring) for 5 minutes, records and compares the data.

[0058] Handling of abnormalities during the experiment: If Mode B detects a 300% surge in the number of particles >14μm within two consecutive cycles, the system will automatically issue a "wear alarm" to alert the tester, who can then choose whether to stop the test for inspection.

[0059] Test completion and maintenance: Stop the test product and the oil supply pump set 7.

[0060] Run the "self-circulating filter" again for 2-3 hours to filter out the wear particles generated during the test and prepare for the next test.

[0061] III. Application Effects The system described in this embodiment has been successfully applied to various types of aerospace gearbox and bearing test benches. Application results show that: Significantly improved lubricating oil quality: Before the test, the cleanliness of the lubricating oil was consistently maintained within NAS 6 level, fundamentally eliminating abnormal wear caused by lubricating oil contamination.

[0062] Outstanding fault warning capability: In a 150-hour endurance test, the system provided an early warning of slight wear on the bearing cage at the 102nd hour through oil return cleanliness monitoring, avoiding catastrophic failure and saving expensive test products.

[0063] Improved testing efficiency: The preheating time is reduced by 60% compared to the traditional method, and the lubricating oil treatment during the test interval is fully automated, reducing the test bench preparation time by about 40%.

[0064] The system operates reliably: the highly integrated design reduces leakage points and failure points, and the remote control of the electric valve avoids errors and risks associated with manual operation.

[0065] In summary, this invention, through innovative flow path integration and valve control design, constructs a powerful, intelligent, and efficient ground tester lubrication system, providing an indispensable foundation for the precise and reliable testing of high-end aviation transmission components. It has extremely high military and economic value and broad prospects for promotion.

[0066] Example 2 Reference Figure 1 This invention enables the manufacturing of complete lubrication system tooling. It provides a highly integrated, multi-functional ground testing instrument lubrication system, functionally divided into three parts: a self-circulating filtration function, a cleanliness detection function, and a self-circulating heating function. These three parts form a cohesive whole, constituting a highly integrated, multi-functional ground testing instrument lubrication system, achieving quality assurance for lubrication simulation of aerospace ground testing instrument products. The solution is as follows: Self-circulating filtration function: The circulating pump group 10 pumps lubricating oil from the lubricating oil tank 8. The remotely controlled filter heating switching valve 12 pumps the lubricating oil to the oil circuit of the filtration system. The lubricating oil in the lubricating oil tank 8 is filtered layer by layer through the 25μm oil filter 20, the 10μm oil filter 19, and the 5μm oil filter 18, making the lubricating oil filtration cleaner and less prone to clogging. Finally, the lubricating oil returns to the lubricating oil tank 8 to form a closed loop. All the above components work together to achieve the self-circulating filtration function.

[0067] Cleanliness detection function: The lubricating oil is pumped from the lubricating oil tank 8 by the oil supply pump group 7. The oil inlet filter 6 ensures the accuracy of the lubricating oil entering the collector 4 and the product. The overflow valve 5 ensures the amount of lubricating oil entering the collector 4 and the product. The oil inlet flow rate is monitored by the turbine flow meter 3. The product inlet oil temperature is controlled by the cooler and the self-circulating heating system. The temperature after adjustment is measured by the temperature sensor 13. The oil supply pressure is measured by the pressure transmitter. Then, the lubricating oil cleanliness of the inlet oil path (A→collector 4→B) or the lubricating oil cleanliness after the product has been working (C→collector 4→D) is controlled online by the oil inlet electric three-way valve 14 and the oil return electric three-way valve 15 respectively. Finally, the lubricating oil is prevented from backflow by the check valve 16 and returns to the lubricating oil tank 8 through the oil return filter 17 to form a closed loop. All the above components work together to realize the cleanliness detection function.

[0068] Online measurement method for lubricating oil cleanliness: The data acquisition unit 4 collects data on different particle sizes of oil samples through a high-temperature particle counter, converts the measurement results into digital values ​​through a built-in remote HMI, and outputs and displays them.

[0069] Self-circulating heating function: The circulating pump group 10 pumps lubricating oil from the lubricating oil tank 8. The remotely controlled filter heating switching valve 12 pumps the lubricating oil to the heating system oil circuit. The heating oil filter 11 ensures the accuracy of the oil entering the constant temperature machine 9 and avoids the constant temperature machine 9 from being blocked. Then the lubricating oil enters the constant temperature machine 9 for circulating heat exchange. Finally, the lubricating oil returns to the lubricating oil tank 8 to form a closed circuit. The above components work together to realize the self-circulating heating function.

[0070] Example 3 See appendix Figure 1 This invention provides a highly integrated and multifunctional lubrication system for a ground testing instrument, the technical solution of which includes: a filtration system, a cleanliness monitoring system, and a heating system; Step 1: The filtration system has the function of cleaning and filtering the lubricating oil of the product, and can perform the filtration function under both operating and non-operating conditions. Step 2: The cleanliness monitoring system is used to monitor the cleanliness status of the product in real time, including the sensors on its inlet and outlet oil lines; Step 3: The heating system has the function of circulating and heating the lubricating oil of the product, and can provide circulating heating under both operating and non-operating conditions; Optionally, the filtration system includes: an inlet oil filter 6, a return oil filter 17, a heated oil filter 11, a 25μm oil filter 20, a 10μm oil filter 19, and a 5μm oil filter 18.

[0071] The inlet oil filter 6 ensures the cleanliness of the lubricating oil entering the product and the collector 4. The return oil filter 17 ensures the cleanliness of the lubricating oil entering the lubricating oil tank 8. The heating oil filter 11 ensures the cleanliness of the lubricating oil entering the constant temperature machine 9. The 25μm oil filter 20, 10μm oil filter 19, and 5μm oil filter 18 perform three-stage filtration of the lubricating oil in the lubricating oil tank 8, effectively improving the lubricating oil cleanliness level.

[0072] Optionally, the cleanliness monitoring system includes: a data collector 4, an inlet electric three-way valve 14, and an outlet electric three-way valve 15.

[0073] The collector 4 is used to measure the cleanliness level of the oil inlet or return path and feeds the measurement results back to the collection system. The electric three-way valve 14 for the oil inlet is used to control the oil inlet of the collector 4, and can be electrically adjusted to select whether to measure the cleanliness of the lubricating oil before or after the product has been used. The electric three-way valve 15 for the oil return is used to control the oil return path of the collector 4, and the measured lubricating oil can be electrically adjusted to select whether to return to the oil inlet or return path of the product.

[0074] Optionally, the cleanliness monitoring system may also include: an oil supply pump group 7 and an overflow valve 5.

[0075] The oil supply pump assembly 7 provides initial kinetic energy for the lubricating oil to enter the collector 4 and the product. The overflow valve 5 controls the amount of lubricating oil entering the collector 4 and the product by adjusting the pressure, and returns excess lubricating oil to the lubricating oil tank 8 through the overflow valve 5.

[0076] Optionally, the cleanliness monitoring system may also include: a radiator 1, a temperature sensor 13, a pressure transmitter 2, a turbine flow meter 3, and a check valve 16.

[0077] The radiator 1 is used to control and regulate the temperature of the lubricating oil entering the collector 4 and the product, and to regulate the heat dissipation by controlling the water flow. The temperature sensor 13 is used to monitor the temperature of the lubricating oil entering the collector 4 and the product. The pressure transmitter 2 is used to monitor the pressure of the lubricating oil entering the collector 4 and the product. The turbine flow meter 3 is used to monitor the flow rate of the lubricating oil entering the collector 4 and the product. The check valve 16 is used to prevent the lubricating oil from being drawn back into the product from the lubricating oil tank 8 when the machine stops working.

[0078] Optionally, the heating system includes: a circulating pump group 10, a thermostat 9, a filter heating switching valve 12, and a lubricating oil tank 8.

[0079] The circulating pump set 10 provides initial kinetic energy for the lubricating oil to enter the self-circulating heating system and the self-circulating filtration system. The thermostat 9 is used to circulate and heat the lubricating oil to prevent carbon buildup. The filter-heating switching valve 12 can be used to remotely control the lubricating oil to enter the self-circulating heating system or the self-circulating filtration system as needed, and can automatically select whether to heat or filter the lubricating oil in the tank.

[0080] Effect: A highly integrated, multi-functional lubrication system for ground testing equipment has been developed and is currently being used on multiple accessory transmission testing equipment. This expands the design possibilities for product lubrication systems and effectively reduces manufacturing costs through the rational switching of electrically controlled valves. This invention enriches the functionality of the lubrication system for engine transmission accessory ground testing equipment, enabling cyclic cleaning in non-operating conditions and cyclic heating in both operating and non-operating states. It also avoids the inaccuracy of oil collection before and after testing, allows for online monitoring of oil cleanliness, timely detection of quality problems, and reduces testing risks. Furthermore, this invention has strong versatility and can be widely promoted and utilized in the future.

[0081] Example 4 This invention discloses a highly integrated, multifunctional lubrication system for a ground testing instrument, comprising: The filtration system has an inlet oil filter, a return oil filter, a heated oil filter, a 25μm oil filter, a 10μm oil filter, and a 5μm oil filter. It has the function of cleaning and filtering the lubricating oil of the product and can perform filtration under both operating and non-operating conditions. The cleanliness monitoring system, which includes a data collector, an inlet electric three-way valve, and a return electric three-way valve, is used to monitor the cleanliness status of the product in real time, including sensors on its inlet and return oil lines. The heating system includes a circulating pump set, a thermostat, a filter heating switching valve, and a lubricating oil tank. It has the function of circulating and heating the lubricating oil of the product and can provide circulating heating under both operating and non-operating conditions.

[0082] Furthermore, the filtration system includes: an inlet oil filter, a return oil filter, a heated oil filter, a 25μm oil filter, a 10μm oil filter, and a 5μm oil filter; The inlet oil filter is used to ensure the cleanliness of the lubricating oil entering the product and the collector. The return oil filter is used to ensure the cleanliness of the lubricating oil entering the lubricating oil tank; The heated oil filter is used to ensure the cleanliness of the lubricating oil entering the constant temperature machine; The 25μm oil filter, 10μm oil filter, and 5μm oil filter are used to perform three-stage filtration of the lubricating oil in the lubricating oil tank, effectively improving the cleanliness level of the lubricating oil.

[0083] Furthermore, the cleanliness monitoring system includes: a data collector, an inlet electric three-way valve, and an outlet electric three-way valve; The data collector is used to measure the cleanliness level of the oil inlet or return line and feeds the measurement results back to the data collection system. The electric three-way valve for oil inlet is used to control the oil inlet path of the collector, and can be electrically adjusted to select the oil cleanliness before or after the product is entered. The electric three-way valve for oil return is used to control the oil return path of the collector. The measured lubricating oil can be electrically adjusted to return to the product's oil inlet path or oil return path.

[0084] Furthermore, the cleanliness monitoring system also includes: an oil supply pump unit and an overflow valve; The oil supply pump set is used to provide initial kinetic energy for the lubricating oil to enter the collector and the product; The overflow valve controls the amount of lubricating oil entering the collector and product by adjusting the pressure, and the excess lubricating oil flows back to the lubricating oil tank through the overflow valve.

[0085] Furthermore, the cleanliness monitoring system also includes: a radiator, a temperature sensor, a pressure transmitter, a turbine flow meter, and a check valve; The radiator is used to control and regulate the temperature of the lubricating oil entering the collector and the product, and to regulate the heat dissipation by controlling the water volume. The temperature sensor is used to monitor the temperature of the lubricating oil entering the collector and the product. The pressure transmitter is used to monitor the pressure entering the data collector and the product lubricating oil; The turbine flow meter is used to monitor the flow rate of the collector and the product lubricating oil. The check valve is used to prevent the lubricating oil from being drawn back into the product from the lubricating oil tank when the product stops working.

[0086] Furthermore, the heating system includes: a circulating pump set, a thermostat, a filter heating switching valve, and a lubricating oil tank; The circulating pump set is used to provide initial kinetic energy for the lubricating oil to enter the self-circulating heating system and the self-circulating filtration system; The constant temperature machine is used to circulate and heat the lubricating oil to prevent carbon buildup in the lubricating oil; The filter-heat switching valve can be used to remotely control the lubricating oil to enter the self-circulating heating system or the self-circulating filtration system, and can choose to heat or filter the lubricating oil in the oil tank, according to actual needs.

[0087] Furthermore, the lubricating oil is pumped out of the lubricating oil tank by the circulating pump unit, and the lubricating oil is pumped to the oil circuit of the filtration system through the remotely controlled filter heating switching valve. The lubricating oil in the lubricating oil tank is filtered layer by layer through 25μm oil filter, 10μm oil filter and 5μm oil filter, so that the lubricating oil filtration is cleaner and the oil filter is less likely to be clogged. Finally, the lubricating oil returns to the lubricating oil tank to form a closed loop. All the above components work together to achieve the self-circulating filtration function.

[0088] Furthermore, the lubricating oil is pumped from the lubricating oil tank by the oil supply pump set, the oil filter at the inlet ensures the accuracy of the lubricating oil entering the collector and the product, the overflow valve ensures the amount of lubricating oil entering the collector and the product, the turbine flow meter monitors the inlet flow rate, the cooler and the self-circulating heating system work together to control the inlet oil temperature of the product, the temperature sensor measures the regulated temperature, the pressure transmitter measures the supply pressure, and the inlet electric three-way valve and the return electric three-way valve control the online measurement of the lubricating oil cleanliness in the inlet circuit, or the online measurement of the lubricating oil cleanliness after the product has been working. Finally, the lubricating oil passes through the check valve to prevent backflow and returns to the lubricating oil tank through the return oil filter to form a closed loop. All of these components work together to achieve the cleanliness detection function.

[0089] Furthermore, online measurement of lubricating oil cleanliness: The data collector uses a high-temperature particle counter to collect data on different particle sizes in the oil sample, and converts the measurement results into digital values ​​via a built-in remote HMI for output and display.

[0090] Furthermore, the lubricating oil is pumped out of the lubricating oil tank by the circulating pump group, and the lubricating oil is pumped to the heating system oil circuit by the remote control filter heating switching valve. The heating oil filter ensures the accuracy of the oil entering the constant temperature machine and avoids the constant temperature machine from being blocked. Then the lubricating oil enters the constant temperature machine for circulation and heat exchange, and finally the lubricating oil returns to the lubricating oil tank to form a closed loop. All the above components work together to achieve the self-circulating heating function.

[0091] The beneficial effects of this application are as follows: 1. This application adopts a three-stage filtration method, which improves the filtration accuracy and makes the oil circuit less prone to clogging.

[0092] 2. This application achieves heating and filtering of lubricating oil in non-working states by setting up a self-circulation system.

[0093] 3. This application controls the amount of lubricating oil in the oil inlet circuit through an overflow valve to achieve sustainable regulation.

[0094] 4. This application uses two electric three-way valves and oil circuits connected in parallel to enable online free testing of lubricating oil cleanliness before and after operation using a single data collector, making it easier to make comparisons.

[0095] 5. This application uses a check valve, which effectively prevents siphoning and eliminates the hidden danger of lubricating oil backflow.

[0096] 6. This application connects all the oil inlet and return lines of the collector to the oil inlet and return lines of the product to prevent the oil inlet and return lines of the product from being affected by the oil collection volume.

[0097] 7. This application uses the combined action of a constant temperature machine and a radiator to control and regulate the temperature of the lubricating oil entering the collector and the product, thus making the lubricating oil regulation range wider.

[0098] 8. This application adopts a dynamic circulation heating method, which makes the lubricating oil heat more evenly and prevents local overheating and carbonization.

[0099] 9. The lubricating oil tank in this application has the same capacity as the engine oil tank to ensure the consistency between the measurement results and the flight operation results.

[0100] 10. This application successfully realizes the multifunctionality of the lubrication system of the engine transmission accessory ground tester, and has the conditions for lubricating oil self-circulation filtration, online cleanliness monitoring and self-circulation heating. By improving the cleaning function, monitoring function and heating function of the lubrication system of the aviation ground tester, the test quality of engine transmission accessories is comprehensively improved.

[0101] Thus, the objective of this invention has been achieved.

[0102] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A highly integrated, multifunctional lubrication system for a ground testing instrument, characterized in that, The system is built around a lubricating oil tank and integrates three interconnected functional flow paths that can work independently or collaboratively, including: The self-circulating filtration path is driven by a circulation pump set and includes a series filtration branch consisting of at least two tank-side oil filters with different filtration accuracies, used for offline circulation and purification of the lubricating oil in the tank when the test product is not working. The product oil supply and cleanliness monitoring flow path is driven by an oil supply pump group and includes a cleanliness collector with a bypass structure. Through the controllable multi-way valve group on the oil inlet side and the oil return side, the collector can be selectively connected in parallel to the product oil inlet pipeline or the product oil return pipeline to realize online, in-situ measurement of the lubricating oil cleanliness at the product inlet or outlet. The self-circulating heating flow path is also driven by the circulating pump group and includes a constant temperature heating device for uniformly and controllably circulating and heating the lubricating oil in the oil tank before or during the operation of the test product. The system also includes a flow path switching valve for controlling the oil flow direction of the circulating pump group, selectively introducing lubricating oil into the self-circulating filter flow path or the self-circulating heating flow path.

2. The highly integrated, multifunctional ground testing instrument lubrication system according to claim 1, characterized in that, The oil tank-side oil filter in the self-circulating filtration path has a multi-stage series structure, including at least a first-stage coarse filter and a second-stage fine filter, with the second-stage fine filter having a higher filtration accuracy than the first-stage coarse filter.

3. The highly integrated, multifunctional ground testing instrument lubrication system according to claim 1, characterized in that, The product oil supply and cleanliness monitoring flow path also includes: An oil filter is installed in the main oil inlet line downstream of the oil supply pump unit; An overflow valve installed in the flow path to regulate and stabilize the lubricating oil pressure and flow rate of the supplied products and the collector; And a sensor array for monitoring fuel supply temperature, pressure and flow.

4. The highly integrated, multifunctional ground testing instrument lubrication system according to claim 3, characterized in that, The controllable multi-way valve group includes an inlet electric three-way valve and a return electric three-way valve; by controlling the inlet electric three-way valve, the oil inlet of the collector can be switched to the product oil inlet pipeline or the product oil outlet pipeline; by controlling the return electric three-way valve, the oil outlet of the collector can be switched to the downstream of the product oil inlet pipeline or the return oil tank pipeline.

5. The highly integrated, multifunctional ground testing equipment lubrication system according to claim 1, characterized in that, The self-circulating heating flow path has a dedicated oil filter for the heating flow path upstream of the constant temperature heating device.

6. The highly integrated, multifunctional ground testing instrument lubrication system according to claim 1, characterized in that, The product oil supply and cleanliness monitoring flow path is equipped with a return oil filter and a check valve to prevent backflow of lubricating oil on the product return oil line.

7. The highly integrated, multifunctional ground testing instrument lubrication system according to any one of claims 1 to 6, characterized in that, The system also includes a radiator integrated into the product oil supply and cleanliness monitoring flow path, located downstream of the oil supply pump group, which is used to work in conjunction with the self-circulating heating flow path to accurately control the lubricating oil temperature supplied to the product.

8. The highly integrated, multifunctional ground testing instrument lubrication system according to any one of claims 1 to 6, characterized in that, The cleanliness collector has a built-in particle counter based on optics or sensors, which can analyze and output the quantity concentration or cleanliness level code of particles of different sizes in the lubricating oil in real time.

9. The highly integrated, multifunctional ground testing instrument lubrication system according to any one of claims 1 to 6, characterized in that, The volume of the lubricating oil tank is proportional to or equal to the actual lubricating oil tank volume of the simulated aircraft engine.

10. A method for conducting ground tests using the lubrication system according to any one of claims 1-9, characterized in that, Includes the following steps: Pre-test preparation stage: Start the circulating pump group, and purify the lubricating oil in the oil tank by operating the flow path switching valve to allow the lubricating oil to flow through the self-circulating filter flow path; and / or, allow the lubricating oil to flow through the self-circulating heating flow path to heat the lubricating oil to the preset test start temperature; Test operation and monitoring phase: Start the oil supply pump group to supply lubricating oil to the test product; by operating the controllable multi-way valve group, connect the cleanliness collector in parallel to the product oil inlet pipeline to monitor the supply cleanliness; then, or as needed, switch the cleanliness collector to connect in parallel to the product oil return pipeline to monitor the return oil cleanliness and compare it with the inlet oil cleanliness. Post-test maintenance phase: After the test, the self-circulating filter flow path is restarted to filter and purify the lubricating oil after use, in preparation for the next test.

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