A hydraulic pump test bench and method thereof

Abstract

The application relates to the technical field of aircraft hydraulic system test equipment, in particular to a hydraulic pump test bench, the test bench is configured with double test channels, can simultaneously or independently test an electric hydraulic pump assembly and an emergency hydraulic pump assembly, and comprises a hydraulic system, a safety protection system, a cooling system, an electric control system and a bearing structure; the hydraulic system respectively provides continuously adjustable oil, adjustable inlet pressure and system simulation pressure for the measured hydraulic pump assembly; the safety protection system independently controls the pressure and flow of each test channel; the cooling system ensures the stability of the test oil; the acquisition unit of the electric control system collects the inlet pressure, the system simulation pressure, the outlet pressure of the measured hydraulic pump assembly, the flow of the pump outlet, the oil temperature and the shell oil return temperature; the control unit dynamically adjusts based on the acquisition data of the acquisition unit. The application provides a hydraulic pump test bench, and solves the problems of single function and low control precision of the existing test bench.

Description

Technical Field

[0001] This invention belongs to the technical field of aircraft hydraulic system testing equipment, specifically relating to a hydraulic pump test bench, which is particularly suitable for performance testing, joint debugging and testing of aircraft electric hydraulic pump components and emergency hydraulic pump components. Background Technology

[0002] Aircraft hydraulic pump components are the core power components of aircraft hydraulic systems, and their performance directly determines the flight safety of aircraft. Therefore, during aircraft production, maintenance, and technical modification, it is necessary to conduct comprehensive performance tests and joint debugging of electric hydraulic pump components and emergency hydraulic pump components through a dedicated hydraulic pump test bench to simulate the hydraulic oil supply conditions in actual aircraft operation and verify the pressure, flow, and temperature adaptability of the pump components.

[0003] Currently, common aircraft hydraulic pump test benches still have the following shortcomings in actual use: The testing functions are relatively limited: Most test benches are single-channel designs, capable of testing only one type of hydraulic pump component at a time. They cannot simultaneously or independently test electric hydraulic pumps and emergency hydraulic pumps, resulting in low equipment utilization and testing efficiency. Furthermore, multiple test benches are required to cover the testing needs of different pump types, increasing equipment costs and space requirements. Control accuracy and the realism of operating condition simulation need improvement: Existing test benches mostly use ordinary relief valves for pressure regulation, making it difficult to achieve continuous, stepless, and precise adjustment of inlet pressure and simulated system pressure. The simulated hydraulic conditions deviate somewhat from the actual aircraft system. This leads to the problems of limited functionality and low control accuracy in existing test benches. Summary of the Invention

[0004] In view of this, the present invention aims to provide a hydraulic pump test bench to solve the problems of limited functionality and low control precision in existing test benches. The specific solution is as follows: A hydraulic pump test bench, the test bench having a dual-test-channel configuration, capable of simultaneously or independently testing an electric hydraulic pump assembly and an emergency hydraulic pump assembly, the test bench comprising: The hydraulic system provides continuously adjustable oil to the suction port of the hydraulic pump assembly under test to simulate the oil supply conditions of an aircraft hydraulic oil tank; provides adjustable inlet pressure to the electric hydraulic pump assembly and the emergency hydraulic pump assembly respectively; and provides adjustable system simulation pressure to the electric hydraulic pump assembly and the emergency hydraulic pump assembly. The safety protection system is connected to the main oil supply pipeline. It prevents the pressure of each test channel from running out of control and prevents the oil contamination level of the oil supply pipeline from exceeding the standard by independently regulating the pressure and flow of each test channel. A cooling system, connected to the system's return oil line, is used to cool and purify the oil whose temperature rises after operation, ensuring the continuity of testing and the stability of oil performance. The electronic control system includes a data acquisition unit and a control unit. The data acquisition unit acquires in real time the inlet pressure, system simulated pressure, outlet pressure of the tested hydraulic pump group, pump outlet flow rate, oil temperature, and housing return oil temperature. The control unit is connected to the data acquisition unit, the hydraulic system, and the safety protection system. The control unit is configured to adjust the inlet pressure, system simulated pressure, and outlet pressure of the tested hydraulic pump group based on the inlet pressure, system simulated pressure, and outlet pressure of the tested hydraulic pump group acquired by the data acquisition unit, and monitor the system safety status; regulate the cooling system based on the acquired oil temperature and housing return oil temperature; perform regulation or alarm actions based on the parameters of the safety protection system; and implement low liquid level alarm based on the oil tank level parameters.

[0005] The load-bearing structure is a vehicle body structure with wheels, used to install the hydraulic system and the electronic control system.

[0006] Preferably, the hydraulic system includes: Oil tanks are used to store and supply working media; The oil suction booster module is shared by two test channels. The inlet of the oil suction booster module is connected to the oil tank, and the outlet is connected to the oil suction port of the two test channels. It is used to steplessly adjust the inlet pressure of the hydraulic pump group under test. The pressure simulation module, with its inlet connected to the oil tank and its outlet connected to the oil supply ports of two test channels, is used to provide adjustable system simulation pressure for the electric hydraulic pump assembly and the emergency hydraulic pump assembly; An auxiliary simulation module is connected between the housing return oil interface of the electric hydraulic pump assembly and the emergency hydraulic pump assembly and the oil tank. The output end of the auxiliary simulation module is connected to the system return oil pipeline. The auxiliary simulation module is used to receive the housing return oil of the tested electric hydraulic pump assembly and emergency hydraulic pump assembly and smoothly guide it back to the oil tank. The safety protection system is respectively installed downstream of the oil suction booster module and the pressure simulation module; The inlet pressure provided by the oil suction booster module is infinitely adjustable from 0.1 MPa to 0.5 MPa; the system simulation pressure provided by the pressure simulation module is infinitely adjustable from 5 MPa to... 31.5 MPa.

[0007] Preferably, the safety protection system has at least two independently configured control branches; The two control branches include a first control branch and a second control branch; The first regulating branch is connected to the outlet pipeline of the electric hydraulic pump assembly and is used to independently regulate and limit the outlet pressure of the electric hydraulic pump assembly; The second control branch is connected to the outlet pipe of the emergency hydraulic pump assembly for independent operation. The outlet pressure of the emergency hydraulic pump assembly is adjusted and limited. The first control branch and the second control branch each include a corresponding adjustment and protection unit and a pollution control unit; The regulating protection unit and the pollution control unit are connected in parallel. The regulating protection unit is used to adjust the load and pressure when the pressure of the corresponding regulating branch exceeds the limit, so as to prevent the pressure of the branch system from running out of control. The contamination control unit is installed on the oil suction line, oil supply line and oil return line respectively, and is used to monitor and control the oil solid particle contamination level in real time. When the oil contamination level exceeds the standard, the self-circulation cleaning mode is activated.

[0008] Preferably, the regulation and protection unit includes a branch controller, a pressure regulation unit, a flow regulation unit, and a safety protection component, which are respectively arranged in parallel on the first regulation branch and the second regulation branch, so as to realize independent control of pressure and flow in each regulation branch and overpressure safety warning.

[0009] Preferably, the pressure regulating unit is a proportional relief valve; the safety protection component is a safety valve; The proportional relief valves are respectively installed at the outlet of the emergency hydraulic pump assembly, the outlet of the electric hydraulic pump assembly, and the outlet of the system pressure simulation module. The proportional relief valves steplessly adjust the pressure at the corresponding positions according to the output signal of the control unit.

[0010] Preferably, the contamination control unit includes an oil suction filter and an oil suction booster filter respectively installed in the oil suction line, an oil supply filter installed in the oil supply line, and an oil return filter installed in the oil return line; The oil suction filter, oil suction booster filter, oil supply filter, and oil return filter are each equipped with a blockage indicator, and the blockage indicator is connected to the control unit. The control unit executes an oil filter blockage alarm based on the status signal received from the blockage transmitter, and controls the contamination control unit to start the self-circulation cleaning mode when the oil contamination level exceeds the standard.

[0011] Preferably, the cooling system is a water-cooled structure, and the cooling system includes a water filter and a radiator; The inlet of the cooling system is connected to an external cooling water source, the hydraulic oil inlet is connected to the test bench's main return oil pipeline, and the outlet is connected to the return oil filter and then to the oil tank. External cooling water enters the radiator after being filtered by a water filter, where it exchanges heat with the high-temperature hydraulic oil in the return oil line, reducing the temperature of the hydraulic oil before flowing back to the oil tank.

[0012] Preferably, the acquisition unit includes a pressure sensor, a flow sensor, a temperature sensor, a liquid level sensor, a pressure gauge, a digital display, and a signal conditioning module; The flow sensors are respectively installed at the outlets of the hydraulic pump units under test in the two test channels to detect the outlet flow of the two test channels respectively. The temperature sensors collect the oil tank temperature and the oil return temperature of the housing in the two test channels, respectively. The pressure sensors are used to detect the inlet pressure, the system simulated pressure, and the pressure at the pump outlet located in the two test channels, respectively. The liquid level sensor is used to collect the liquid level height in the oil tank and realize low liquid level alarm.

[0013] Preferably, the control unit includes an industrial computer, and analog input boards, analog output boards, digital input / output boards, and a main communication card, all connected to the industrial computer. The analog input board receives analog signals from the data acquisition unit, and the control unit outputs control signals to the first pressure regulating unit, the second pressure regulating unit, and the third pressure regulating unit through the analog output board, respectively, to achieve stepless pressure regulation of each unit. The digital input / output board is used to process switch signals; The industrial control computer has built-in control logic to realize pressure closed-loop regulation, real-time monitoring of temperature, liquid level and contamination level, safety interlock protection and test data acquisition and analysis. At the same time, it communicates with the control box of the hydraulic pump component under test through a bus communication card to read and display electrical performance-related parameters.

[0014] Preferably, the control logic built into the industrial control computer calculates and displays the performance curve of the tested hydraulic pump component in real time based on the collected outlet pressure and flow data, and supports the storage, playback, printing of test data and automatic generation of test reports.

[0015] Compared with the prior art, the beneficial effects of this application are as follows: This test bench, with its dual test channels, allows a single test bench to simultaneously or independently test an electric hydraulic pump assembly and an emergency hydraulic pump assembly, eliminating the need for multiple dedicated test benches and improving equipment utilization and testing efficiency. The hydraulic system, electrical control system, safety protection system, and cooling system within this test bench are relatively independent, making fault diagnosis, maintenance, and subsequent upgrades and modifications of each functional unit more convenient, thus improving system maintainability and scalability. Furthermore, all of these independent systems are integrated into a mobile vehicle structure with wheels, allowing the test bench to move between different test stations or work sites to meet the mobility requirements of aircraft hydraulic pump sites.

[0016] In this application, the hydraulic system features an inlet pressure that is infinitely adjustable within the range of 0.1MPa to 0.5MPa, accurately simulating the oil supply pressure conditions provided by the aircraft hydraulic tank to the hydraulic pump, thus reproducing the actual pump inlet working conditions. The hydraulic system also features a system simulation pressure that is infinitely adjustable within the range of 5MPa to 31.5MPa, capable of providing continuously variable load pressure to the outlet of the pump under test, thereby simulating the actual working load of the aircraft hydraulic system. A dedicated auxiliary simulation module is installed between the return oil interface of the pump housing and the oil tank, capable of receiving and guiding the leaked oil from the pump housing back to the oil tank smoothly, simulating the pump housing return oil back pressure and flow rate under real working conditions, making the test environment closer to reality. A shared suction booster module is set up for the dual test channels, providing the pump under test with sufficient flow and stable pressure suction conditions, ensuring the stability of the pump suction process, especially simulating the pressurized oil tank working conditions that may exist on an aircraft. The diameters of the suction pipe, pressure pipe, and return pipe are determined according to a limited flow velocity, i.e., ≤2m / s, ≤7m / s, respectively. The calculation and selection of flow rate (≤3m / s) effectively controlled the oil flow rate in the pipeline, thereby reducing pipeline pressure loss, fluid noise, and oil temperature rise caused by excessive flow rate. The connection pipeline between the test bench and the pump under test uses fluoroplastic hoses, the internal pump body connection uses rubber hoses, and the joints use aviation standard ED ring seals with German standard, which improves the sealing reliability and vibration resistance of the pipeline connection, while facilitating assembly, disassembly, and interchangeability.

[0017] In the safety protection system, each test channel is equipped with an independent control branch, ensuring that the testing processes of the electric pump and the emergency pump do not interfere with each other. They can be independently set and protected, preventing the failure of one channel from affecting the other. Proportional relief valves are installed as pressure regulating units in each control branch and at key system locations, achieving high-precision, continuous, and stepless electrical proportional control of inlet pressure, system simulated pressure, and pump outlet pressure, thus improving the accuracy and response characteristics of pressure control. Mechanical safety valves are installed in parallel in each key pressure circuit, with a set pressure of 32.0±0.5MPa, providing hardware overpressure protection independent of electrical control. When the pressure unexpectedly exceeds the limit, it can automatically open to release pressure, preventing damage to pipelines or components. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the hydraulic pump test bench in one embodiment of the present invention; Figure 2 This is a block diagram of the control unit in a hydraulic pump test bench according to one embodiment of the present invention; Figure 3 This is a hierarchical design diagram of the software system in a hydraulic pump test bench according to an embodiment of the present invention; List of components and reference numerals: 1. Oil tank; 2. Suction filter; 3. Suction booster pump assembly; 3-1. Suction booster pump suction port; 3-2. Suction booster pump auxiliary interface; 3-3. Suction booster pump outlet; 4. Suction booster oil filter; 5. Suction check valve; 6. Suction pressure gauge; 7. System simulation pressure sensor; 8. Oil supply pressure sensor; 8-1. First oil supply pressure sensor; 8-2. Second oil supply pressure sensor; 9. Oil supply flow sensor; 9-1. First oil supply flow sensor; 9-2. Second oil supply flow sensor 10. Quantity sensor; 10. Oil supply check valve; 10-1. Oil supply check valve for emergency pump branch; 10-2. Oil supply check valve for electric pump branch; 10-3. Third oil supply check valve; 11. Flow sensor; 12. Pressure regulating valve; 12-1. Emergency pump outlet pressure regulating valve; 12-2. Electric pump outlet pressure regulating valve; 12-3. System simulation pressure regulating valve; 13. Safety valve; 13-1. First safety valve (emergency pump outlet); 13-2. Second system safety valve (system simulation pressure pipe) 14. Flow regulating valve; 14-1. First flow regulating valve; 14-2. Second flow regulating valve; 14-3. Third flow regulating valve; 15. Suction booster relief valve; 16. Suction booster safety valve; 17. Suction booster bypass valve; 18. Radiator; 19. Water filter; 20. Return oil filter; 21. Air filter; 22. Liquid level and temperature gauge; 23. Emergency hydraulic pump assembly; 23-1. Emergency hydraulic oil suction port; 23-2. Emergency hydraulic pump outlet; 23-3, 24. Electric Hydraulic pump assembly; 24-1, Electric hydraulic pump assembly suction port; 24-2, Electric hydraulic pump assembly outlet port; 24-3, Electric hydraulic pump assembly interface; 25, System pressure simulation module; 25-1, First pump body interface; 25-2, Second pump body interface; 25-3, Third pump body interface; 26, Housing return oil temperature sensor; 26-1, First housing temperature sensor; 26-2, Second housing temperature sensor; 27, Oil tank temperature sensor; 28, Oil drain switch; 29, System pressure gauge. Detailed Implementation

[0019] According to one embodiment of this application, a hydraulic pump test bench is provided. The test bench is a dual-channel configuration, capable of simultaneously or independently testing an electric hydraulic pump assembly and an emergency hydraulic pump assembly. The test bench includes: The hydraulic system simulates the oil supply conditions of an aircraft hydraulic tank by providing continuously adjustable oil to the suction port of the hydraulic pump assembly under test (specifically, an electric hydraulic pump assembly or an emergency hydraulic pump assembly); it simulates the load of an aircraft hydraulic system by providing continuously adjustable simulated system pressure to the oil supply port of the hydraulic pump assembly under test; and it simulates the oil return conditions of the housing of the hydraulic pump assembly under test, thereby providing a realistic simulated working environment of an aircraft hydraulic system for the hydraulic pump under test. In this application, the hydraulic system uses fluoroplastic hoses (connected to the test bench and the hydraulic pump assembly under test) and rubber hoses (connected to the pump body inside the test bench), and the pipe joints adopt an aerospace standard with a German standard ED ring for sealing.

[0020] The safety protection system is connected to the main oil supply pipeline. It prevents the pressure of each test channel from running out of control and prevents the oil contamination level of the oil supply pipeline from exceeding the standard by independently regulating the pressure and flow of each test channel. The cooling system, connected to the system's return oil line, is used to cool and purify the oil whose temperature rises after operation, so as to ensure that the oil temperature is always maintained within the allowable operating range, and to ensure the continuity of testing and the stability of oil performance.

[0021] The electronic control system includes a data acquisition unit and a control unit. The data acquisition unit collects in real time the inlet pressure, system simulated pressure, outlet pressure of the tested hydraulic pump group, pump outlet flow rate, oil temperature, and housing return oil temperature. The control unit is connected to the data acquisition unit, the hydraulic system, and the safety protection system. The control unit is configured to adjust the inlet pressure, system simulated pressure, and outlet pressure of the tested hydraulic pump group based on the inlet pressure, system simulated pressure, and outlet pressure of the tested hydraulic pump group acquired by the data acquisition unit, and monitor the system safety status; regulate the cooling system based on the collected oil temperature and housing return oil temperature; perform regulation or alarm actions based on the parameters of the safety protection system; and implement low liquid level alarm based on the oil tank level parameters.

[0022] The load-bearing structure is a vehicle body structure with wheels, used to install the hydraulic system and the electronic control system.

[0023] Furthermore, the hydraulic system includes: The oil tank is used to store the working medium for the test bench described in this application, and serves as the... It has a starting point and an ending point for the oil circuit, providing a stable working medium for the entire hydraulic system; The oil suction booster module has its inlet connected to the oil tank and its outlet connected to two... The oil suction port of the test channel is used for stepless adjustment of the inlet pressure of the hydraulic pump unit under test; for the pump under test The group's oil suction port provides a continuous, adjustable, and sufficient flow of oil, simulating the fuel supply conditions of an aircraft's fuel tank. Ensure an oil supply flow rate ≥ 60 L / min; simultaneously, provide an adjustable inlet pressure to the tested hydraulic pump to achieve... The inlet pressure is infinitely adjustable from 0.1MPa to 0.5MPa, thereby simulating the fuel supply conditions and inlet working conditions of an aircraft fuel tank. The pressure simulation module, with its inlet connected to the oil tank and its outlet connected to the oil supply ports of the two test channels, is used to provide adjustable system simulation pressure for the electric hydraulic pump assembly and the emergency hydraulic pump assembly; the pressure simulation module is independently configured for each test channel; and the system simulation pressure is infinitely adjustable from 5MPa to 31.5MPa. An auxiliary simulation module is connected between the housing return oil interface of the electric hydraulic pump assembly and the emergency hydraulic pump assembly and the oil tank. The output end of the auxiliary simulation module is connected to the system return oil pipeline. The auxiliary simulation module is used to receive the housing return oil of the tested electric hydraulic pump assembly and emergency hydraulic pump assembly and smoothly guide it back to the oil tank; simulate the real housing return oil working condition and buffer the return oil pressure fluctuation.

[0024] Furthermore, the safety protection system has at least two independently configured control branches; The two control branches include a first control branch and a second control branch; The first regulating branch is connected to the outlet pipeline of the electric hydraulic pump assembly and is used to independently regulate and limit the outlet pressure of the electric hydraulic pump assembly; The second control branch is connected to the outlet pipe of the emergency hydraulic pump assembly for independent operation. The outlet pressure of the emergency hydraulic pump assembly is adjusted and limited. The first control branch and the second control branch each include a corresponding adjustment and protection unit and a pollution control unit; The regulating protection unit and the pollution control unit are connected in parallel. The regulating protection unit is used to adjust the load and pressure when the pressure of the corresponding regulating branch exceeds the limit, so as to prevent the pressure of the branch system from running out of control. The contamination control unit is installed on the oil suction line, oil supply line and oil return line respectively, and is used to monitor and control the oil solid particle contamination level in real time. When the oil contamination level exceeds the standard, the self-circulation cleaning mode is activated.

[0025] Furthermore, the regulation and protection unit includes a branch controller, a pressure regulation unit, a flow regulation unit, and a safety protection component, which are respectively connected in parallel on the first regulation branch and the second regulation branch, so as to realize independent control of pressure and flow in each regulation branch and overpressure safety warning.

[0026] The branch controller is an independent control module located on each control branch in the electrical control system, used to achieve local closed-loop regulation of pressure and flow in the corresponding test channel. Each control branch is equipped with one branch controller, which is communicatively connected to the control unit, receives pressure and flow setting commands from it, and independently drives the proportional relief valve and flow regulating valve on that branch based on real-time pressure and flow signals acquired by the acquisition unit, achieving precise pressure and flow control in its branch. The branch controller can be an embedded microcontroller (MCU) or a programmable logic controller (PLC), which connects to the proportional relief valve, flow regulating valve, pressure sensor, and flow sensor through digital / analog input / output interfaces, forming a closed-loop control loop independent of other branches. This enables independent and parallel control of pressure and flow in each test channel, reducing the real-time control burden on the main control unit (industrial computer), improving system response speed and control accuracy; and when one branch fails, it does not affect the normal operation of other branches.

[0027] The pressure regulating unit is a proportional relief valve; the safety protection component is a safety valve. The proportional relief valves are respectively installed at the outlet of the emergency hydraulic pump assembly, the outlet of the electric hydraulic pump assembly, and the outlet of the system pressure simulation module. The proportional relief valves steplessly adjust the pressure at the corresponding positions according to the output signal of the control unit.

[0028] The safety protection component is a safety valve.

[0029] The pressure regulating unit includes a first pressure regulating unit, a second pressure regulating unit, and a third pressure regulating unit. The safety valve includes a first safety valve, a second safety valve, and a third safety valve. The first pressure regulating unit and the first safety valve are installed in parallel at the outlet of the oil suction boosting module. The second installation valve and the second pressure regulating unit are installed in parallel at the outlet of the pressure simulation module. The third safety valve and the third pressure regulating unit are installed in parallel downstream of the oil supply line of each test channel. The first pressure regulating unit and the first safety valve, the second mounting valve and the second pressure regulating unit, and the third safety valve and the third pressure regulating unit are respectively connected to the electronic control system; The electronic control system controls the closing of the first safety valve, the second safety valve, and the third safety valve based on the detected inlet pressure, the simulated system pressure, and the measured hydraulic pump outlet pressure, and adjusts the first pressure regulating unit, the second pressure regulating unit, and the third pressure regulating unit.

[0030] The opening pressures of the first safety valve, the second safety valve, and the third safety valve are set to be higher than the rated working pressure of the test bench; the opening pressure of the safety valve is 32.0±0.5MPa, the closing pressure is not less than 29.5MPa, and the fully open pressure is not greater than 34.0MPa.

[0031] The first pressure regulating unit, the second pressure regulating unit, and the third pressure regulating unit are all proportional relief valves.

[0032] The contamination control unit further includes oil filters installed in the oil suction line, oil supply line, and oil return line; specifically, it includes an oil suction filter and an oil suction booster filter installed in the oil suction line, an oil supply filter installed in the oil supply line, and an oil return filter installed in the oil return line. Each oil filter is equipped with a blockage indicator, and the blockage indicator is connected to the control unit. The control unit executes an oil filter blockage alarm based on the status signal received from the blockage transmitter.

[0033] In this application, the oil filter at the suction port has a 10μm bypass structure, and all oil filters are equipped with an electrically charged blockage indicator, which is electrically connected to the control unit. The filter has a βx ≥ 1000 and a filtration efficiency of 99.9%. When the control unit receives a signal from the blockage indicator, it executes an audible and visual alarm for oil filter blockage. When the oil contamination level exceeds the standard, the control unit controls the contamination level control unit to start the self-circulation cleaning mode.

[0034] Furthermore, the oil suction booster module is an oil suction booster pump, used to provide an adjustable inlet pressure for the hydraulic pump under test; The pressure simulation module is a pressure simulation pump used to simulate the load of an aircraft hydraulic system and provide adjustable system simulation pressure for the hydraulic pump under test.

[0035] Furthermore, the cooling system is water-cooled, and the cooling system includes a water filter and a radiator; The inlet of the cooling system is connected to an external cooling water source, the hydraulic oil inlet is connected to the test bench's main return oil pipeline, and the outlet is connected to the return oil filter and then to the oil tank. External cooling water enters the radiator after being filtered by a water filter, where it exchanges heat with the high-temperature hydraulic oil in the return oil line, reducing the temperature of the hydraulic oil before flowing back to the oil tank. Furthermore, the control unit includes an industrial computer, and analog input boards, analog output boards, and digital input / output boards respectively connected to the industrial computer; The analog input board receives analog signals from the data acquisition unit, and the control unit outputs control signals to the first pressure regulating unit, the second pressure regulating unit, and the third pressure regulating unit through the analog output board, respectively, to achieve stepless pressure regulation of each unit. The digital input / output board is used to process switch signals.

[0036] The control unit outputs control signals to the first pressure regulating unit, the second pressure regulating unit, and the third pressure regulating unit through an analog output board, so as to realize stepless adjustment of their respective pressures.

[0037] Specifically: The control unit controls the first pressure regulating unit based on the inlet pressure collected by the data acquisition unit to maintain the inlet pressure of the tested hydraulic pump within a set range; it controls the second pressure regulating unit based on the collected system simulation pressure signal to make the system simulation pressure reach a set value; and it independently controls each of the third pressure regulating units based on the test requirements and the collected outlet pressure to adjust the outlet pressure of the corresponding tested hydraulic pump group. The control unit monitors the temperature signal and the status of the first safety valve, and executes an alarm or shutdown protection when the limit is exceeded; The digital input / output board is used to process switching signals. Specifically, the analog input board is used to receive analog signals from the data acquisition unit, the analog output board is used to output control signals to the proportional relief valve, and the digital input / output board is used to process digital signals for oil filter blockage alarm, liquid level alarm, and emergency stop switch.

[0038] In this application, the control unit is also equipped with a bus communication module. The control unit communicates with the control box of the hydraulic pump under test through the bus communication module to read and display electrical performance parameters.

[0039] Furthermore, the test bench also includes a support structure; the support structure is used to integrate and install the hydraulic system and the electrical control system to form a movable platform.

[0040] In this application, the load-bearing structure includes a chassis frame and wheels disposed at the bottom of the chassis to form a movable vehicle body, wherein the vehicle body has an openable protective cover surrounding the hydraulic system and the electronic control system; the protective cover is provided with an operation panel, which integrates a touch screen, an emergency stop button, a motor start / stop switch and status indicator lights.

[0041] In this application, the industrial control computer has built-in control logic, and the industrial control computer calculates and displays the performance curve of the tested hydraulic pump in real time based on the outlet pressure and flow data collected by the acquisition unit.

[0042] The present application is described in detail below with reference to the embodiments, but the present application is not limited to these embodiments.

[0043] Example 1 like Figure 1 As shown, this embodiment provides a specific dual-channel hydraulic pump test bench. It is suitable for testing an electric hydraulic pump assembly and an emergency hydraulic pump assembly for a certain type of aircraft. The electric hydraulic pump assembly has a rated flow rate of 30 L / min and a full-flow pressure of 25.6 MPa, while the emergency hydraulic pump assembly has a rated pressure of 13.3 MPa and a rated flow rate of 20 L / min.

[0044] The test bench in this embodiment includes a hydraulic system, a safety protection system, a cooling system, a data acquisition unit, a control unit, and a load-bearing structure.

[0045] In this embodiment, the hydraulic system specifically includes: The effective volume of oil tank 1 is not less than 70L. An EF3-40 type air filter is installed on the top, a KYW-250 type liquid level and temperature gauge and an oil tank temperature sensor are installed on the side wall, and an oil tank drain switch 28 is provided at the bottom. The working medium in oil tank 1 is 15# aviation hydraulic oil. The oil contamination control level is not worse than GJB 420B-8, and the acceptance level is not worse than GJB 420B-7.

[0046] The oil in tank 1 is drawn into the suction booster pump assembly 3 via suction filter 2. After being boosted, the oil passes through suction booster filter 4 and suction check valve 5, then splits into two paths, which are respectively delivered to the suction ports of the tested emergency hydraulic pump assembly 23 and electric hydraulic pump assembly 24. Suction pressure gauge 6 monitors the inlet pressure in real time, and the control unit adjusts the opening of suction booster overflow valve 15 to achieve stepless precise control of the inlet pressure of the tested pump within the range of 0.1MPa to 0.5MPa. The oil tank drain switch 28 is connected to the drain port at the bottom of tank 1 and is used to drain the hydraulic oil in tank 1 during maintenance or oil change. An air filter 21 is installed at the top opening of tank 1 and is connected to the internal cavity of tank 1. It is used to balance the air pressure inside and outside tank 1 and filter impurities in the air entering tank 1 to prevent air from carrying impurities and contaminating the oil.

[0047] The oil suction booster module is specifically the oil suction booster pump set 3, which uses an Asada DVQ25-52 vane pump with a displacement of 52cc / rev and is equipped with a 1.5kW motor. The outlet of the oil suction booster pump set 3 is connected to the suction port of the pump under test via an oil suction booster oil filter, an oil suction booster overflow valve, and an oil suction booster safety valve. The oil supply flow rate of the oil suction booster pump set 3 is ≥60L / min. The oil suction booster pump set 3 is a triple-unit structure, such as... Figure 1The three-unit structure of the suction booster pump assembly 3 shown consists of a booster pump suction port 3-1, a booster pump auxiliary interface 3-2, and a booster pump outlet 3-3. The booster pump suction port 3-1 is connected to the oil tank 1 via the suction filter 2; the booster pump outlet 3-3 is connected to the input end of the suction booster oil filter 4. The suction booster pump assembly 3 provides booster power for the system's suction process, improving the main pump's suction stability and ultimately achieving stepless adjustment of the inlet pressure from 0.1 to 0.5 MPa. This provides the tested pump assembly with sufficient flow and stable pressure oil to simulate the oil supply conditions of an aircraft hydraulic tank. The electric hydraulic pump assembly 24 has a multi-port pump body structure, specifically including an electric hydraulic pump assembly suction port 24-1, an electric hydraulic pump assembly outlet port 24-2, and an electric hydraulic pump assembly interface 24-3. The electric hydraulic pump assembly suction port is connected to the suction booster pipeline via a suction check valve 5, and the electric hydraulic pump assembly outlet port 24-2 is connected to the main oil supply pipeline.

[0048] The emergency hydraulic pump assembly 23 and the electric hydraulic pump assembly 24 are symmetrically arranged. The oil suction port 23-1 of the emergency hydraulic pump is also connected to the oil suction booster pipeline via the oil suction check valve 5. The oil outlet port 23-2 of the emergency hydraulic pump merges with the oil outlet port 24-2 of the electric hydraulic pump assembly and is connected to the main oil supply pipeline to realize stepless adjustment of the simulated system pressure from 5 to 31.5 MPa, simulating the load pressure of the aircraft hydraulic system.

[0049] The simulated pressure supply loop draws oil from tank 1, and the output oil passes through proportional relief valve 12-3 and safety valve 13-2. The simulated system pressure can be steplessly set within the range of 5MPa to 31.5MPa by adjusting proportional relief valve 12-3. This pressure is applied to the oil supply ports of the two pumps under test through pipelines to simulate the load of the aircraft hydraulic system.

[0050] The system simulates pump 25 as a control-type pump body structure, and its interfaces are as follows: Figure 1 The first pump body interface 25-1, the second pump body interface 25-2, and the third pump body interface 25-3 shown are connected at the input end to the return oil pipeline of the housing of the emergency hydraulic pump assembly 23 and the electric hydraulic pump assembly 24, and at the output end to the system return oil pipeline. The system simulation pump 25 receives the leaked oil from the housing of the tested electric / emergency hydraulic pump assembly, simulates the leakage flow and pressure fluctuation under real working conditions, and buffers the return oil pressure impact to avoid the pressure fluctuation of the oil tank caused by the direct backflow of the leaked oil.

[0051] The flow rate / power and pipe diameter of the oil suction booster pump were theoretically calculated. The parameters were selected based on the following criteria: pressure pipe velocity V≤7m / s, return pipe velocity V≤3m / s, and suction pipe velocity V≤2m / s. The calculation results all meet the technical requirements. The pipe diameters selected for the test bench are: pressure pipe 10mm, return pipe 25mm, and suction pipe 30mm. The specific calculation process is as follows: 1. Calculation of flow rate of oil suction booster pump Q = q × n / 1000 Where: Q is the flow rate, L / min; q is the pump displacement, mL / r; n is the motor speed, r / min; Calculation: Q = 52 × 1500 / 1000 = 78 L / min ≥ 60 L / min, which meets the technical requirements.

[0052] 2. Calculation of the motor power of the oil suction booster pump N = P × Q / (60η) In the formula: N is the motor power, kW; P is the system pressure, MPa; Q is the flow rate, L / min; η is the pump efficiency, taken as 0.9; Calculation: N = 0.5 × 78 / (60 × 0.9) = 0.72 kW. Select a 1.5 kW motor to ensure sufficient power reserve.

[0053] 3. Pressure pipe diameter calculation d≥1130*{Q / (60*1000*V)} 1 / 2 In the formula: d is the pipe diameter, mm; Q is the flow rate, L / min; V is the flow velocity in the pipe, m / s; V is taken as the maximum value of 7 m / s, then: d=1130*{Q / (60*1000*V)} 1 / 2 =1130*{30 / (60*1000*7)} 1 / 2 =9.55mm Therefore, d = 10mm meets the requirements.

[0054] 4. Calculation of return oil pipe diameter d≥1130*{Q / (60*1000*V)} 1 / 2 In the formula: d is the pipe diameter, mm; Q is the flow rate, L / min; V is the flow velocity in the pipe, m / s, with V taking the maximum value of 3 m / s, then: d = 1130 * {Q / (60 * 1000 * V)} 1 / 2 =1130*{60 / (60*1000*3)} 1 / 2 =20.63mm, so d =25mm meets the requirements.

[0055] 5. Calculation of oil suction pipe diameter d≥1130*{Q / (60*1000*V)} 1 / 2 In the formula: d is the pipe diameter, mm; Q is the flow rate, L / min; V is the flow velocity in the pipe, m / s, with V taking the maximum value of 2 m / s, then: d = 1130 * {Q / (60 * 1000 * V)} 1 / 2 =1130*{78 / (60*1000*2)} 1 / 2 =28.8mm, so d =30mm meets the requirements.

[0056] 6. Calculation of Radiator Heat Dissipation Area Formula: S = (40 - 2) × 0.027 = 1.026m 2 The Shaanxi Sutai ST059 brazed plate radiator was selected, with a matching heat dissipation area to meet the cooling requirements.

[0057] In this embodiment, the independent control and monitoring loop of the test channel is specifically as follows: Emergency Pump Channel: After the emergency hydraulic pump assembly 23 is operational, the output oil flows through its independent control branch. This branch consists of a second flow sensor 9-1, a second proportional relief valve 12-1, and a second safety valve 13-1. The proportional relief valve 12-1 is used to precisely regulate the outlet pressure of this channel, the flow sensor 9-1 is used to monitor the outlet flow, and the safety valve 13-1 provides overpressure protection.

[0058] After the electric hydraulic pump assembly 24 is activated, the oil it outputs flows through its independent control branch. This branch consists of a first flow sensor 9-2, a first proportional relief valve 12-2, and a third safety valve 13-3, and functions the same as the emergency pump channel.

[0059] The pressure and flow data of the two channels are collected in real time by the first oil supply pressure sensor 8-1, the second oil supply pressure sensor 8-2, the first flow sensor 9-1, and the second flow sensor 9-2.

[0060] In this embodiment, the cooling system includes a water filter 19 and a radiator 18. The water filter 19 is a filtration component for the external cooling medium. In this embodiment, the cooling medium is water. The input end of the water filter 19 is connected to an external cooling water source, and the output end is connected to the cooling medium inlet of the radiator 18 to filter impurities in the cooling water and prevent blockage of the cooling channels in the radiator 18. The input end of the hydraulic oil side of the radiator 18 is connected to the system's main return oil pipeline, and the output end is connected to the return oil filter 20. The cooling medium side and the water filter 19 form a loop. The outlet oil from the two tested pumps and the return oil from the housing are monitored by the first temperature sensor 26-1 and the second housing temperature sensor 26-2, merging into the system's main return oil. The main return oil flows through the radiator 18, exchanging heat with the externally supplied cooling water to lower the oil temperature to a set range of -10℃ to 70℃. The cooled oil is then filtered again by the return oil filter 20 and returned to the oil tank, completing the circulation.

[0061] In this embodiment, the safety protection system is connected to the main oil supply pipeline, and each test channel is independently configured with a control branch. Each control branch is connected in parallel with a regulation protection unit and a contamination control unit to achieve independent control of pressure and flow, overpressure protection, oil contamination monitoring, and self-circulation cleaning. The specific configuration is as follows: The regulating and protection unit includes a branch controller connected in parallel for each branch, a pressure regulating unit, a flow regulating unit, and safety protection components. The pressure regulating units are all proportional relief valves, the flow regulating units are flow regulating valves, and the safety protection components are safety valves. Stepless pressure regulation is achieved through the proportional relief valves, and hardware overpressure protection is provided through the safety valves. The opening pressure is 32.0±0.5MPa, the closing pressure is ≥29.5MPa, and the fully open pressure is ≤34.0MPa. When the branch pressure exceeds the limit, the safety valve automatically opens to relieve the pressure and prevent damage to the pipeline and pump body. The oil supply check valve 10 includes a first oil supply check valve 10-1 and a second oil supply check valve 10-2 connected in series at the front end of the control branch of the emergency pump and the electric pump outlet, respectively, and a third oil supply check valve 10-3 connected in series at the front end of the main oil supply control branch of the system. This is to prevent backflow of oil in each control branch, ensure unidirectional flow of oil in each branch, and avoid mutual interference between branches.

[0062] Pressure regulating valve 12 includes three regulating valves: a first pressure regulating valve 12-1 located in the emergency pump branch, a second pressure regulating valve 12-2 located in the electric pump branch, and a third pressure regulating valve 12-3 located at the outlet of the system pressure simulation pump. The first pressure regulating valve 12-1, the second pressure regulating valve 12-2, and the third pressure regulating valve 12-3 are all connected in series to the downstream end of the flow sensor 11 of their respective branches. Their input ends are connected to the high-pressure oil supply, and their output ends are connected to the return oil pipeline. This allows for independent adjustment of the oil supply pressure of each branch, enabling independent regulation of the pressure of the emergency pump, the electric pump, and the system's total oil supply, matching the pressure requirements of different operating conditions, and achieving stepless pressure regulation. Safety valve 13 includes a first safety valve 13-1 located in the emergency pump branch, a second safety valve 13-2 located in the electric pump branch, and a third safety valve 13-3 located in the main branch of the system. The first safety valve 13-1, the second safety valve 13-2, and the third safety valve 13-3 are connected in parallel to the downstream end of the pressure regulating valve 12 of their respective branches. Their input ends are connected to the pipeline after the regulating valve, and their output ends are connected to the return oil pipeline. Their function is to provide overpressure safety protection for each regulating branch. When the branch pressure exceeds the safety valve's set value, it automatically opens to unload and relieve pressure, preventing damage to the branch pipeline and actuators.

[0063] The flow regulating valve 14 includes a first flow regulating valve 14-1 located in the emergency pump branch, a second flow regulating valve 14-2 located in the electric pump branch, and a third flow regulating valve 14-3 in the main branch of the system. The first flow regulating valve 14-1, the second flow regulating valve 14-2, and the third flow regulating valve 14-3 are connected in series at the rear end of the safety valve 13 of their respective branches, serving as the end flow control components for each branch. Their function is to separately adjust the output flow of each branch, achieving graded and precise control of the system's oil supply flow to meet the flow requirements of different actuators.

[0064] The suction check valve 5 is connected in series in the output pipeline of the suction booster oil filter 4, with the valve core flowing in the direction from the suction booster pump to the main pump. It is used to prevent the oil in the main oil supply circuit from flowing back to the suction booster pump, ensuring the one-way flow of the suction pipeline.

[0065] The pressure regulating valve 15 is connected in parallel to the pipeline at the output end of the suction booster oil filter 4. The input end of the pressure regulating valve 15 is connected to the boosted pipeline, and the output end is connected to the return oil pipeline. The working pressure threshold of the suction booster circuit is set to achieve precise adjustment of the suction booster pressure.

[0066] Safety valve 16 and pressure regulating valve 15 are arranged in parallel. The input end of safety valve 16 is connected to the oil suction booster pipeline, and the output end is connected to the oil return pipeline. Safety valve 16 serves as an overpressure safety protection component for the oil suction booster circuit. When the circuit pressure exceeds the set value, it automatically opens to unload and prevent the pipeline and pump body from being damaged due to overpressure.

[0067] The suction booster bypass valve 17 is connected in parallel across the suction booster oil filter 4 and is normally closed. When the suction booster oil filter 4 becomes clogged or the pressure difference exceeds the set value, the suction booster bypass valve 17 automatically opens to bypass the oil and ensure that the oil supply to the suction booster circuit is not interrupted.

[0068] The contamination control unit is an oil filter. Each oil filter is equipped with an electrically connected blockage indicator, which is electrically connected to the control unit. When the control unit receives a blockage indicator signal, it triggers an audible and visual alarm. If the contamination level exceeds the standard, a self-circulation cleaning mode is activated to ensure that the oil contamination control level is no worse than GJB 420B-8 and the acceptance level is no worse than GJB420B-7. The oil filters specifically include a suction filter 2, a suction booster filter 4, and a return filter 20; wherein: The input end of the suction filter 2 is directly connected to the oil outlet of the oil tank 1, and the output end is connected to the oil inlet 3-1 of the suction booster pump group 3, connecting them in series between the oil tank 1 and the suction booster pump group 3 to filter impurities in the oil drawn into the suction booster pump group 3 from the oil tank 1. The input end of the suction booster oil filter 4 is connected to the pump body auxiliary interface 3-2, and the output end is connected to the main suction oil pipeline of the system. This allows for secondary filtration of the oil pressurized by the suction booster pump group, further purifying the oil entering the main oil supply circuit.

[0069] The input end of the return oil filter 20 is connected to the oil outlet of the radiator 18, and the output end is connected to the return oil outlet of the oil tank 1, connected in series between the return oil cooling circuit and the oil tank. By filtering impurities in the cooled system return oil, the oil flowing back to the oil tank is purified, ensuring the cleanliness of the oil in the oil tank.

[0070] In this embodiment, in addition to pressure and contamination protection, the safety protection system is also linked with the acquisition unit to achieve temperature interlock and liquid level interlock. When the oil tank temperature exceeds the limit (≥115±5℃), the shell oil return temperature exceeds the limit (≥130℃), or the oil tank liquid level is low, the control unit first issues an audible and visual alarm. If the parameters continue to exceed the limit, the machine will automatically stop to protect the test bench and the tested pump components.

[0071] like Figure 2 As shown, in this embodiment, the acquisition unit includes a pressure sensor, a flow sensor, a temperature sensor, a liquid level sensor, a mechanical pressure gauge, a digital display, and an intermediate conditioning module. The output terminals of all sensors are hard-connected to the input terminals of the intermediate conditioning module. The intermediate conditioning module filters, amplifies, and linearizes the signals from various sensors before outputting them to the control unit's board.

[0072] The control unit is equipped with an industrial computer and includes a board, a touch display, a digital display, an alarm device, a communication module, and an HB6096. The board is connected to the output of the intermediate conditioning module, converts analog signals into digital signals and sends them to the industrial computer. At the same time, it receives control commands from the industrial computer, converts them into analog / digital signals and outputs them to actuators such as proportional relief valves, motors, and cooling systems. The touch screen and digital display are embedded in the test bench's operation panel and communicate with the industrial control computer. The touch screen enables setting test parameters, operating equipment, displaying performance curves, and retrieving test reports, while the digital display shows key parameters such as inlet pressure, system simulated pressure, outlet flow rate, and oil temperature in real time. The alarm device is an audible and visual alarm connected to an industrial control computer. In case of abnormalities such as oil filter blockage, low oil level, oil overheating, or system overpressure, the industrial control computer triggers an audible and visual alarm. The communication module is standardized and compatible with the HB6096. The industrial control computer establishes ARINC 429 bus communication with the test piece control box (the electric / emergency hydraulic pump assembly has its own control box) through the communication module and HB6096 to read the electrical performance parameters of the pump under test, such as voltage, current, and speed, and displays them on a touch screen / digital display. The system simulates pressure proportional relief valve 12-3 and the first proportional relief valve 12-1 and the second proportional relief valve 12-2 of the two test channels are all connected to the analog output terminal of the board. The industrial control computer outputs pressure adjustment commands according to the test requirements, which are converted into electrical signals by the board and then drive the proportional relief valves to achieve stepless and precise adjustment of the inlet pressure of 0.1MPa~0.5MPa and the system simulated pressure of 5MPa~31.5MPa.

[0073] In this embodiment, the acquisition unit is specifically configured as follows: The probe of the level and temperature gauge 22 extends into the interior of the oil tank 1 and is installed on the side wall of the oil tank. It is used to monitor the level and temperature of the hydraulic oil in the oil tank 1 in real time, providing intuitive monitoring data for system oil replenishment and temperature warning; the level sensor is integrated with the level and temperature gauge 22 to collect the level of the oil in the oil tank 1 and realize low level alarm. Two flow sensors are installed in total, with a range of 0-66 L / min and an accuracy of ±0.5% FS. They are installed at the outlet of the pump under test in two test channels. Temperature sensor: Three are provided, one of which is an oil tank temperature sensor 27 that monitors the oil temperature in oil tank 1 in real time. Its probe extends into the interior of oil tank 1 and is installed on the side wall of oil tank. Two housing temperature sensors 26 measure the housing return oil temperature, including a first housing temperature sensor 26-1 corresponding to the emergency hydraulic pump assembly and a second housing temperature sensor 26-2 corresponding to the electric hydraulic pump assembly. The probes of the first housing temperature sensor 26-1 and the second housing temperature sensor 26-2 are respectively connected to the emergency hydraulic pump assembly interface 23-3 and the electric hydraulic pump assembly interface 24-3. The signal outputs are aggregated and connected to the control unit to monitor the housing return oil temperature of the emergency hydraulic pump assembly and the electric hydraulic pump assembly in real time, reflecting the pump body's operating temperature rise and providing signal basis for pump overload and overheat protection. In this embodiment, the oil tank temperature alarm threshold is 115±5℃, the housing return oil temperature alarm threshold is 130℃, and the alarm delay is ≤6s.

[0074] The flow sensors include an oil supply flow sensor 9 and a flow sensor 11. The oil supply flow sensor 9 includes a first oil supply flow sensor 9-1 connected in series with the main oil outlet line of the emergency hydraulic pump assembly 23, and a second oil supply flow sensor 9-2 connected in series with the main oil outlet line of the electric hydraulic pump assembly 24, which monitor the oil flow at the outlet of the emergency hydraulic pump assembly 23 and the electric pump 24 in real time, respectively, to provide data feedback for flow regulation. The flow sensor 11 includes a first flow sensor 11-1 connected in series with the rear end of the oil supply check valve 10-1 and the front end of the pressure regulating valve 12-1 of the emergency pump branch; the second flow sensor 11-2 is connected in series with the rear end of the oil supply check valve 10-2 and the front end of the pressure regulating valve 12-2 of the electric pump branch, in order to monitor the oil flow before pressure regulation of each branch and realize the coordinated monitoring of flow and pressure.

[0075] The pressure sensors include an oil supply pressure sensor 8 and an oil suction pressure sensor 7, and each pressure sensor is equipped with a WIKA 100 mechanical pressure gauge; The oil supply pressure sensor 8 includes a first oil supply pressure sensor 8-1 and a second oil supply pressure sensor 8-2 arranged in parallel with the first oil supply flow sensor 9-1 and the second oil supply flow sensor 9-2, respectively; it monitors the oil supply pressure at the outlet of the emergency hydraulic pump assembly 23 and the electric pump 24 in real time, and converts the pressure signal into an electrical signal output.

[0076] The suction pressure sensor 7 is connected in parallel to the suction line between the suction check valve 5 and the main pump. Its function is to monitor the pressure at the suction port of the main pump and provide feedback on the working effect of the suction booster circuit.

[0077] The mechanical pressure gauges include a suction pressure gauge 6 and a system pressure gauge 29. The suction pressure gauge 6 is connected in parallel with the suction pressure sensor 7 and is a mechanical pointer-type instrument. Its function is to visually display the pressure value of the suction pipeline on-site, facilitating manual inspection and adjustment. The system pressure gauge 29 is connected in series at the end of the main oil supply pipeline of the system, connected to the main oil supply outlet. Its function is to visually monitor the final output oil supply pressure of the system on-site, providing a direct basis for system pressure setting and fault diagnosis.

[0078] In this embodiment, the control logic of the control unit is implemented based on control software. The control software enables parameter setting, pressure closed-loop regulation, real-time data acquisition and display, performance curve plotting, data storage (txt / lst / png / jpg formats), automatic generation of test reports, fault audible and visual alarms / interlock shutdown, and can also read the electrical performance parameters of the pump component under test through the ARINC429 bus, supporting data playback and printing.

[0079] The control software runs on an industrial computer, and its architecture is as follows: Figure 3As shown, a layered modular design is adopted to realize parameter setting, automatic testing, real-time data display, curve plotting, data storage, report generation, and comprehensive security monitoring and interlocking logic. In this embodiment, this layered, multi-threaded, modular program structure effectively simplifies the coupling and deployment between modules, improves test throughput, and enhances program execution efficiency.

[0080] The core layer, primarily based on the hardware and operating system kernel, provides the software runtime environment and stable hardware APIs; the core layer is the foundation for the operation of the test bench system, and a stable hardware and software environment is crucial for the reliable operation of the test bench. The resource layer includes analog signal acquisition and output control functions, 429 bus communication control functions, 422 bus communication control functions, and digital signal acquisition and output functions. The resource layer is the tentacles of the test bench, serving the input and output control of the test bench through the resources provided by the resource layer. The business layer, based on the data resources required by the software logic operations and software module components, implements data verification, logical processing, transaction management, records business processing logs, and throws business exception information according to the corresponding algorithms. The application layer provides a user interface, controls the corresponding software components and hardware resources to perform corresponding input and output tasks according to user operations, and provides a feedback mechanism to return the execution results to the user; it also provides diverse display methods such as charts, curves, and indicator lights to display the calculation results, making it convenient for users to make intuitive judgments on the experimental results.

[0081] When the system starts up, it first calls sub-function modules such as 429, 422, analog, and digital inputs to prepare various necessary resources for the system. Once the resources are allocated and the hardware is functioning normally, it begins to execute the corresponding control outputs according to predefined parameters and logic.

[0082] Each submodule process handles only its own resources. The processing includes reading board data, analyzing the data, and sending the data to the main system. The control process is handled by the main system, which performs logical integration, data encapsulation, and writing to the device cache.

[0083] The main system receives data from each submodule, performs integrated display, and the specific execution flow depends on... Depending on the requirements. Control information from each functional interface is transmitted to each sub-functional module through the main system.

[0084] In this embodiment, the load-bearing structure is a movable vehicle body with non-marking solid wheels, using a high-quality carbon steel bent and welded chassis. It has four-wheel drive, with two rear wheels as the main load-bearing drive wheels and two front wheels as steering wheels. It can be hoisted as a whole, turning flexibly without damaging the ground. The vehicle body has openable doors on all four sides for easy installation and maintenance. The operation panel is divided into a display panel, a digital display, and an operation switch panel, which are independently separated from the hydraulic system and electrical control unit by a partition. It integrates a touch screen, power switch, emergency stop button, buzzer alarm, motor start / stop switch, and temperature / oil filter / liquid level alarm indicator lights, with a layout that conforms to ergonomics. The hydraulic pipeline includes 6 custom fluoroplastic hoses and 6 custom rubber hoses. The pipe joints adopt an aviation standard with a German standard ED ring sealing method, which has strong interchangeability and reliable sealing. The test bench is connected to an external AC380V, 50Hz three-phase five-wire power supply. The operating environment temperature is -10℃~+40℃, humidity <85%, and operating noise ≤80dB.

[0085] The specific operating procedure for this test bench is as follows: S1, Experiment Preparation: Move the test bench to the test station and connect it to an AC380V three-phase five-wire power supply, then introduce cooling water into the cooling system. Install the electric hydraulic pump assembly and / or emergency hydraulic pump assembly under test at the corresponding test station on the test bench. Use fluoroplastic hoses to connect the oil inlet and outlet of each hydraulic pump under test to the hydraulic interface of the corresponding channel on the test bench; and connect the communication interface of the control box of the hydraulic pump assembly under test to the bus corresponding to the control unit.

[0086] Start the industrial control computer and touch display, run the dedicated control software, and complete the hardware self-test and communication link check.

[0087] S2, Set test parameters: The target inlet pressure can be set steplessly within the range of 0.1-0.5MPa, the system simulated pressure can be set steplessly within the range of 5-31.5MPa, and the pump outlet pressure and safety alarm thresholds (tank / shell return oil temperature, liquid level, oil filter blockage) via the touch display. Confirm the safety monitoring thresholds, including the oil tank over-temperature alarm temperature of 115±5℃, the shell oil return alarm temperature of 130℃, the oil filter blockage alarm threshold, and the low liquid level alarm threshold.

[0088] S3: Hydraulic system startup and pressure build-up The control unit sequentially starts the oil suction booster module and the oil supply module through the control logic or operation panel buttons: the oil suction booster pump group is started, and the control unit adjusts the inlet pressure of the hydraulic pump suction port to the target value set in step S2 by controlling the oil suction booster overflow valve based on the feedback signal of the oil suction pressure sensor. The system pressure simulation module is activated. Based on the feedback signal from the system simulation pressure sensor, the control unit adjusts the system simulation pressure to the target value set in step S2 by controlling the third proportional relief valve 12-3.

[0089] Once the above settings are completed, the control logic will indicate that the system is ready to enter the performance testing phase.

[0090] S4: Start-up and performance testing of the pump under test The control unit sends a start command to the tested electric hydraulic pump assembly or emergency hydraulic pump assembly, and the tested pump enters the working state. The control unit executes a preset test program based on control logic. By controlling the first or second proportional relief valve of the corresponding channel, the outlet pressure of the hydraulic pump under test is continuously and precisely loaded and adjusted to simulate different working conditions. During this process, the acquisition unit collects and displays data in real time: Real-time parameters such as inlet pressure, system simulated pressure, pump outlet pressure, pump outlet flow, oil tank temperature, and casing return oil temperature are used to control the electrical performance parameters read from the control box of the pump under test via a communication bus.

[0091] In steps S3 and S4 above, the control unit continuously monitors the following safety parameters and executes protective actions according to preset logic when abnormalities occur, specifically: Monitor the status of each oil filter blockage indicator to monitor the level of contamination. If a blockage signal is triggered, an audible and visual alarm will be issued on the control panel.

[0092] The system continuously compares the oil tank temperature and the shell return oil temperature with the set threshold to monitor the temperature. When the temperature reaches the alarm value (e.g., oil tank temperature ≥115±5℃, shell return oil temperature ≥130℃), the system will issue an alarm and trigger automatic shutdown.

[0093] Monitor the oil tank level and trigger an alarm when the level is low.

[0094] Pressure monitoring is performed. If the system pressure rises abnormally and exceeds the safety valve's set opening pressure (e.g., 32.0 ± 0.5 MPa), the corresponding safety valve will automatically open to release pressure, providing final hardware protection.

[0095] Furthermore, during the test, the operator can press the emergency stop button on the control panel at any time to cut off the main power supply.

[0096] After all tests are completed, the unloading procedure is executed via the control software. The control unit controls each proportional relief valve to gradually relieve system pressure.

[0097] The test hydraulic pump, system pressure simulation module, and oil suction booster pump group are stopped sequentially, and the cooling system control unit is shut down. The test data is stored as a local file, supporting the generation of performance curves and test reports as needed, which can be directly printed or exported as electronic files. Finally, the hydraulic pipelines and communication cables connected to the pump components under test are disconnected, the main power supply of the test bench and external water and electricity connections are turned off, and the test site is cleaned up.

[0098] Example 2 This embodiment, as an optimization scheme for improving the versatility of functions and equipment utilization in Embodiment 1, addresses the shortcomings of traditional test benches, which suffer from limited functionality and low equipment utilization due to fixed hardware parameters and rigid testing procedures. The specific solution is as follows: In this embodiment, the control unit is configured to execute a set of dynamic resource allocation logic. To achieve rapid matching for different pump types under test, the specific solution is as follows: The control unit pre-stores standard test parameter sets corresponding to various models of hydraulic pump components. The standard test parameter sets define the inlet pressure range, system simulation pressure range, safety threshold, etc. required for testing the pump assembly of each model.

[0099] Once the operator selects the specific model of the test pump group for a particular test channel, the control unit automatically calls the corresponding standard parameter set for the test pump group and executes the following coordinated control actions: Based on the inlet pressure parameters in the standard test parameter set, it drives the proportional relief valve in the oil suction booster module to precisely stabilize the oil suction pressure of the channel at the target value; based on the called system simulation pressure parameters, it drives the proportional relief valve in the pressure simulation module to establish the corresponding load back pressure environment; and simultaneously, it loads the safety thresholds (such as temperature and contamination level) in this parameter set into the independent monitoring logic of the channel for synchronous configuration of the safety monitoring logic. Because the same set of physical sensors and proportional valve hardware is instantly reconfigured for different test pump group types in different test tasks, this solves the problems of low efficiency and error-proneness caused by manually adjusting parameters item by item, as well as the equipment idleness and limited functionality caused by the inability of the equipment to quickly switch test objects, and realizes rapid adaptation of a single device to multiple test pump models.

[0100] To fully leverage the parallel capabilities of the dual-test-channel hardware in Embodiment 1, in this embodiment, the control unit is also configured to manage independent and asynchronous test tasks for each of the two test channels. Specifically, different test sequences are preset for each test channel; for example, one test channel performs a durability test, while the other performs a performance scan test. The control unit, through its multi-threading, independently and synchronously drives the proportional relief valves of the two test channels, collects sensor data, and executes test steps. Furthermore, through built-in resource arbitration logic, it coordinates the two test channels' competitive access to the shared cooling system and oil tank resources. Specifically, when high load operation of both test channels causes an excessively rapid rise in oil temperature, the arbitration logic can prioritize the cooling needs of one test channel or automatically insert a pause period into the test sequence of the other test channel. This multi-threading and resource arbitration approach solves the equipment waiting and idling issues caused by traditional sequential testing, ensuring that both test channels operate at high efficiency and improving equipment utilization.

[0101] Example 3 This embodiment, as an optimization scheme of Embodiment 1, achieves the staticization of simulated operating conditions to match the dynamic environment of real flight. The specific implementation scheme is as follows: The control unit is configured to execute a control strategy with predictive and coupled adjustment capabilities, which achieves high dynamic fidelity simulation of operating conditions by predicting the system's dynamic response and coordinating the actuators. Specifically: To address the inherent response delay issue of pure feedback control in Embodiment 1, the control unit incorporates a feedforward control loop during closed-loop regulation. This enables the system pressure to rapidly track load changes during simulated flight without lag or overshoot. Specifically, upon receiving a rapid pressure change command, the control unit adjusts based on real-time feedback signals from the pressure sensor while simultaneously outputting a pre-calculated compensation control signal to the corresponding proportional relief valve based on pre-stored system dynamic response commands. This counteracts the inherent pressure build-up inertia of the hydraulic system, achieving proactive adjustment of the proportional relief valve. Through this operation, the pressure response lag and overshoot caused by oil compressibility and pipeline cavity effects are effectively eliminated, ensuring a high degree of consistency between the load pressure change curve simulated on the test bench and the load demand curve of the actual aircraft control surface actions.

[0102] To address the issue that static back pressure simulation in traditional hydraulic testing cannot accurately reflect flight conditions, this embodiment employs a control unit that dynamically and continuously adjusts the opening of the proportional relief valve associated with the system's return oil pipeline based on a preset timing control script simulating aircraft climbs and dives. This makes the shell return oil back pressure a dynamic parameter that changes over time, simulating the impact of acceleration and attitude on the internal environment of the hydraulic system during real flight. This allows for accurate reproduction of the changing shell return oil environment during flight maneuvers. The control unit monitors the change in shell return oil temperature in real time during dynamic back pressure adjustment and performs pressure-temperature coupling analysis based on the thermodynamic properties of the oil. When the analysis results indicate that the rising oil temperature may exceed the system's safety threshold or deviate from real operating conditions, the control unit actively activates the cooling system to increase heat dissipation or adaptively adjusts the dynamic back pressure control script. Through the coordinated control of the pressure-temperature coupling effect, the problem of static back pressure simulation failing to accurately reflect flight conditions in traditional hydraulic testing is solved, achieving accurate reproduction of the complex physical states under the real flight profile.

[0103] The above description is merely a few embodiments of this application and is not intended to limit this application in any way. Although this application discloses preferred embodiments as described above, it is not intended to limit this application. Any changes or modifications made by those skilled in the art without departing from the scope of the technical solution of this application using the disclosed technical content are equivalent to equivalent implementation cases and fall within the scope of the technical solution.

Claims

1. A hydraulic pump test bench, characterized in that, The test bench is configured with dual test channels, capable of simultaneously or independently testing one electric hydraulic pump assembly and one emergency hydraulic pump assembly. The test bench includes: The hydraulic system provides continuously adjustable oil to the suction port of the hydraulic pump assembly under test to simulate the oil supply conditions of an aircraft hydraulic oil tank; provides adjustable inlet pressure to the electric hydraulic pump assembly and the emergency hydraulic pump assembly respectively; and provides adjustable system simulation pressure to the electric hydraulic pump assembly and the emergency hydraulic pump assembly. The safety protection system is connected to the main oil supply pipeline. It prevents the pressure of each test channel from running out of control and prevents the oil contamination level of the oil supply pipeline from exceeding the standard by independently regulating the pressure and flow of each test channel. A cooling system, connected to the system's return oil line, is used to cool and purify the oil whose temperature rises after operation, ensuring the continuity of testing and the stability of oil performance. The electronic control system includes a data acquisition unit and a control unit. The data acquisition unit acquires in real-time inlet pressure, system simulated pressure, outlet pressure of the tested hydraulic pump assembly, pump outlet flow rate, oil temperature, and housing return oil temperature. The control unit is connected to the data acquisition unit, the hydraulic system, and the safety protection system. The control unit is configured to adjust the inlet pressure, system simulated pressure, and outlet pressure of the tested hydraulic pump assembly based on the inlet pressure, system simulated pressure, and outlet pressure of the tested hydraulic pump assembly acquired by the data acquisition unit, and monitor the system safety status; regulate the cooling system based on the acquired oil temperature and housing return oil temperature; perform regulation or alarm actions based on parameters of the safety protection system; and implement low-level alarm based on oil tank level parameters. The load-bearing structure is a vehicle body structure with wheels, used to install the hydraulic system and the electronic control system.

2. The hydraulic pump test bench according to claim 1, characterized in that, The hydraulic system includes: Oil tanks are used to store and supply working media; The oil suction booster module is shared by two test channels. The inlet of the oil suction booster module is connected to the oil tank, and the outlet is connected to the oil suction port of the two test channels. It is used to steplessly adjust the inlet pressure of the hydraulic pump group under test. The pressure simulation module, with its inlet connected to the oil tank and its outlet connected to the oil supply ports of two test channels, is used to provide adjustable system simulation pressure for the electric hydraulic pump assembly and the emergency hydraulic pump assembly; An auxiliary simulation module is connected between the housing return oil interface of the electric hydraulic pump assembly and the emergency hydraulic pump assembly and the oil tank. The output end of the auxiliary simulation module is connected to the system return oil pipeline. The auxiliary simulation module is used to receive the housing return oil of the tested electric hydraulic pump assembly and emergency hydraulic pump assembly and smoothly guide it back to the oil tank. The safety protection system is respectively installed downstream of the oil suction booster module and the pressure simulation module; The inlet pressure provided by the oil suction booster module is infinitely adjustable from 0.1MPa to 0.5MPa; the system simulation pressure provided by the pressure simulation module is infinitely adjustable from 5MPa to 31.5MPa.

3. A hydraulic pump test bench according to claim 2, characterized in that, The security protection system is equipped with at least two independent control branches; The two control branches include a first control branch and a second control branch; The first control branch is connected to the outlet pipeline of the electric hydraulic pump assembly and is used to independently adjust and limit the outlet pressure of the electric hydraulic pump assembly; The second control branch is connected to the outlet pipe of the emergency hydraulic pump assembly for independent operation. The outlet pressure of the emergency hydraulic pump assembly is adjusted and limited. The first control branch and the second control branch each include a corresponding adjustment and protection unit and a pollution control unit; The regulating protection unit and the pollution control unit are connected in parallel. The regulating protection unit is used to adjust the load and pressure when the pressure of the corresponding regulating branch exceeds the limit, so as to prevent the pressure of the branch system from running out of control. The contamination control unit is installed on the oil suction line, oil supply line and oil return line respectively, and is used to monitor and control the oil solid particle contamination level in real time. When the oil contamination level exceeds the standard, the self-circulation cleaning mode is activated.

4. A hydraulic pump test bench according to claim 3, characterized in that, The regulation and protection unit includes a branch controller, a pressure regulation unit, a flow regulation unit, and a safety protection component, which are respectively connected in parallel on the first and second regulation branches, so as to realize independent control of pressure and flow in each regulation branch and overpressure safety warning.

5. A hydraulic pump test bench according to claim 4, characterized in that, The pressure The regulating unit is a proportional relief valve; the safety protection component is a safety valve. The proportional relief valves are respectively installed at the outlet of the emergency hydraulic pump assembly, the outlet of the electric hydraulic pump assembly, and the outlet of the system pressure simulation module. The proportional relief valves steplessly adjust the pressure at the corresponding positions according to the output signal of the control unit.

6. A hydraulic pump test bench according to claim 3, characterized in that, The contamination control unit includes an oil suction filter and an oil suction booster filter respectively installed in the oil suction line, an oil supply filter installed in the oil supply line, and an oil return filter installed in the oil return line. The oil suction filter, oil suction booster filter, oil supply filter, and oil return filter are each equipped with a blockage indicator, and the blockage indicator is connected to the control unit. The control unit executes an oil filter blockage alarm based on the status signal received from the blockage transmitter, and controls the contamination control unit to start the self-circulation cleaning mode when the oil contamination level exceeds the standard.

7. A hydraulic pump test bench according to claim 3, characterized in that, The cooling system is a water-cooled structure, and the cooling system includes a water filter and a radiator; The inlet of the cooling system is connected to an external cooling water source, the hydraulic oil inlet is connected to the test bench's main return oil pipeline, and the outlet is connected to the return oil filter and then to the oil tank. External cooling water enters the radiator after being filtered by a water filter, where it exchanges heat with the high-temperature hydraulic oil in the return oil line, reducing the temperature of the hydraulic oil before flowing back to the oil tank.

8. A hydraulic pump test bench according to claim 3, characterized in that, The acquisition unit includes a pressure sensor, a flow sensor, a temperature sensor, a liquid level sensor, a pressure gauge, a digital display, and a signal conditioning module; The flow sensors are respectively installed at the outlets of the hydraulic pump units under test in the two test channels to detect the outlet flow of the two test channels respectively. The temperature sensors collect the oil tank temperature and the oil return temperature of the housing in the two test channels, respectively. The pressure sensors are used to detect the inlet pressure, the system simulated pressure, and the pressure at the pump outlet located in the two test channels, respectively. The liquid level sensor is used to collect the liquid level height in the oil tank and realize low liquid level alarm.

9. A hydraulic pump test bench according to claim 3, characterized in that, The control unit includes an industrial computer, and analog input boards, analog output boards, digital input / output boards, and a main communication card, all connected to the industrial computer. The analog input board receives analog signals from the data acquisition unit, and the control unit outputs control signals to the first pressure regulating unit, the second pressure regulating unit, and the third pressure regulating unit through the analog output board, respectively, to achieve stepless pressure regulation of each unit. The digital input / output board is used to process switch signals; The industrial control computer has built-in control logic to realize pressure closed-loop regulation, real-time monitoring of temperature, liquid level and contamination level, safety interlock protection and test data acquisition and analysis. At the same time, it communicates with the control box of the hydraulic pump component under test through a bus communication card to read and display electrical performance-related parameters.

10. A hydraulic pump test bench according to claim 9, characterized in that, The control logic built into the industrial computer calculates and displays the performance curve of the tested hydraulic pump component in real time based on the collected outlet pressure and flow data, and supports the storage, playback, printing of test data and automatic generation of test reports.

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