A flexible sealing assembly state simulation tester

Abstract

This invention discloses a flexible seal assembly state simulation tester, specifically relating to the field of brush seal testing. It includes a base on which a test assembly is mounted. The test assembly includes a support frame positioned on top of the base, a pad in the middle of the support frame, and a sealing pressure plate for pressurization on top of the pad. This invention integrates core functions such as axial movement simulation, high-temperature and high-pressure leakage simulation, vibration load simulation, dynamic lifting test, and bidirectional load simulation. Through the organic coordination of the transmission structure of the motor, lifting screw, and brush seal sleeve, the vibration generation structure of the swashplate and vibrating ball, the bidirectional transmission structure of the traction rod and sliding column, and the high-temperature and high-pressure air circuit system, it can simultaneously reproduce the high-temperature and high-pressure, axial movement, vibration impact, and bidirectional load coupling conditions faced by the brush seal in the host machine. This solves the technical defect of traditional equipment's single-condition simulation being disconnected from real-world scenarios, providing a realistic test environment for brush seal performance testing.

Description

Technical Field

[0001] This invention relates to the field of brush seal testing technology, and more specifically, to a flexible seal assembly state simulation tester. Background Technology

[0002] As a core sealing component of high-end power equipment such as aero-engines and gas turbines, brush seals directly determine the energy conversion efficiency, operational reliability, and service life of the equipment. These components operate in extremely harsh environments: they must withstand the scouring of high-temperature combustion gases exceeding 550°C and high-pressure differentials exceeding 2MPa for extended periods. Simultaneously, they must cope with periodic vibrations, axial movement (ranging from 0-20mm), and bidirectional load impacts caused by the high-speed rotation of the rotor. The combined effects of these complex operating conditions can easily lead to brush seal wear, deformation, or even failure, resulting in serious problems such as equipment leakage and reduced efficiency.

[0003] However, current performance verification of brush seals faces many technical bottlenecks: On the one hand, the main structures of aircraft engines are complex and the manufacturing costs are extremely high (hundreds of millions of yuan per unit). Directly conducting brush seal assembly status, leakage characteristics and operating condition adaptability tests on the whole machine is not only costly, but also poses a huge risk of seal failure leading to damage to the whole machine. On the other hand, during the operation of the whole machine, the working status of the brush seal is affected by a combination of factors such as combustion chamber temperature, rotor speed and airflow disturbance. The test data suffers from a serious "multi-factor aliasing" problem, making it impossible to isolate the performance defects of the brush seal itself and making it difficult to accurately locate the cause of its failure.

[0004] While a few existing technologies exist for simulating and testing brush seals, most can only simulate single operating conditions (such as simple high-pressure leakage tests or axial displacement tests). They cannot reproduce real-world scenarios involving multiple operating conditions such as high temperature and high pressure, axial movement, vibration loads, and bidirectional forces. This results in significant discrepancies between test results and actual working conditions, failing to provide reliable data support for brush seal structural optimization and performance improvement. Therefore, developing a flexible seal assembly state simulation tester that can comprehensively and accurately simulate the real working conditions of brush seals, achieve simultaneous detection of multi-dimensional performance parameters, and is cost-effective and low-risk has become an urgent technical need in this field. Summary of the Invention

[0005] In order to overcome the above-mentioned defects of the prior art, the present invention provides a flexible sealing assembly state simulation tester, which aims to solve the problems mentioned in the background art.

[0006] The present invention provides the following technical solution: a flexible sealing assembly state simulation tester, including a base, on which test components are disposed; The test assembly includes a support frame set on the top of the base, a pad in the middle of the support frame, a sealing plate for pressurization on the top of the pad, a pressure sensor between the pad and the sealing plate, and several support blocks on the top of the pressure sensor. The axial movement of the brush seal is simulated by the pad deforming under force and squeezing the support blocks. The pressure sensor has a sliding column at its bottom, which is embedded in a pad. The bottom of the pad has an air inlet for air intake, and the sealing plate has an air outlet for exhaust. High-temperature and high-pressure gas is introduced into the air inlet to create a pressure difference on both sides of the brush seal, and a flow meter is arranged at the air outlet to detect the leakage of the brush seal and simulate the leakage characteristics of the brush seal.

[0007] Optionally, in one possible implementation, the test assembly further includes a rotating cylinder disposed at the bottom of the inner cavity of the support frame. A first swashplate is disposed at the bottom of the rotating cylinder, and a second swashplate is disposed at the bottom of the first swashplate. A plurality of vibrating balls are disposed between the first and second swashplates. When the second swashplate rotates, the torque is transmitted to the vibrating balls. The vibration generated by the rotation of the vibrating balls is transmitted to the first swashplate, simulating the load of a brush seal subjected to vibration. A ramp is respectively opened on the adjacent side of the first and second swashplates. The first swashplate is lifted by rotating the second swashplate to change the slope angle of the second swashplate for dynamic testing. A plurality of support rods are disposed at the bottom of the second swashplate, and a hinged ball is fixedly disposed at the top of each support rod. The plurality of hinged balls extend to the bottom of the second swashplate and are hinged to the second swashplate.

[0008] Optionally, in one possible implementation, a drive motor for rotating the second swashplate is provided at the bottom of the second swashplate. A mounting plate is provided at the bottom of the drive motor, and the mounting plate is bolted to the base. The bottom end of the support rod extends to the base and is slidably connected to the base. The drive motor drives the second swashplate to rotate, changing the tilt angle of the second swashplate and forcing the first swashplate to be lifted and lowered by force. A slot is provided on one side of the bottom of the slide column and one side of the top of the rotating drum, and a traction rod is provided in both slots. The vertical displacement of the first swashplate drives the rotating drum to pull the traction rod to move, which in turn drives the slide column to move, in order to simulate bidirectional load under the brush seal state.

[0009] Optionally, in one possible implementation, mounting frames are respectively provided at both ends of the pad, and each mounting frame is provided with an electric slide rail. The position of the mounting frame is adjusted by the electric slide rail, thereby adjusting the height of the pad. A processor is embedded in the base, and a motor is provided at the top of the support frame. A lifting screw is provided at the output end of the motor. A brush seal sleeve is threaded to the outer side of the lifting screw. The bottom end of the brush seal sleeve is installed on the sealing pressure plate. The motor drives the lifting screw to rotate, and the lifting screw applies a load downward to the sealing pressure plate. The deformation of the sealing pressure plate causes the support pad to deform. The pressure is detected by a pressure sensor, thereby causing the brush seal sleeve to move axially, simulating the axial movement of the brush seal.

[0010] The technical effects and advantages of this invention are as follows: 1. This invention integrates the core functions of axial movement simulation, high temperature and high pressure leakage simulation, vibration load simulation, dynamic lifting test and bidirectional load simulation. Through the organic cooperation of the transmission structure of motor, lifting screw and brush seal sleeve, vibration generation structure of swashplate and vibrating ball, bidirectional transmission structure of traction rod and slide column and high temperature and high pressure air circuit system, it can synchronously reproduce the high temperature and high pressure, axial movement, vibration impact and bidirectional load coupling working conditions faced by brush seal in the host. It solves the technical defects of traditional equipment single working condition simulation and disconnection from real scene, and provides a test environment that fits the reality for brush seal performance testing. 2. Based on the multi-condition collaborative simulation capability, this invention can collect and analyze key parameters such as pressure, leakage, displacement, and vibration frequency in real time through the linkage of pressure sensor, flow meter and processor. Moreover, the simulation and detection of each condition are independent of each other and can be coordinated and controlled. While simulating axial movement, the leakage change can be detected simultaneously to accurately determine the impact of movement on sealing performance. 3. This invention, through a combination of vibration load and bidirectional load testing, can separate the effects of different stress forms on brush seal wear. This design completely solves the problem of data aliasing in whole-machine testing, and can individually locate specific defects in brush seals in terms of assembly accuracy, material properties, and structural design, providing precise targets for technical improvement; 4. This invention does not require testing of the entire host machine. Through simulation in a laboratory environment, it significantly reduces the direct costs such as equipment wear and downtime losses caused by testing the entire machine, while avoiding the high risk of host machine damage caused by seal failure. Attached Figure Description

[0011] To more clearly illustrate the technical solutions in this disclosure, the accompanying drawings used in some embodiments will be briefly described below. Obviously, the drawings described below are only drawings of some embodiments of this disclosure, and those skilled in the art can obtain other drawings based on these drawings. In addition, the drawings described below can be regarded as schematic diagrams and are not intended to limit the actual size of the product, the actual flow of the method, the actual timing of the signals, etc. involved in the embodiments of this disclosure.

[0012] Figure 1 This is a front view of the overall structure of the present invention.

[0013] Figure 2 This is a side view of the overall structure of the present invention.

[0014] Figure 3 This is a schematic diagram of the base, support frame, sealing pressure plate, brush seal thread sleeve, sealing pressure plate and vibrating ball of the present invention.

[0015] Figure 4 This is a schematic diagram of the pad, mounting plate, drive motor, electric slide rail, mounting frame, and rotating drum of the present invention.

[0016] Figure 5 This is a schematic diagram of the sliding column, rotating cylinder, first swashplate, second swashplate, drive motor, pressure sensor, and support pad of the present invention.

[0017] Figure 6 This is a schematic diagram of the first swashplate, the second swashplate, and the support rod of the present invention.

[0018] Figure 7 For the present invention Figure 6 Exploded view.

[0019] Figure 8 This is a schematic diagram of the drive motor, rotating drum, sliding column, traction rod, slot, and sliding column of the present invention.

[0020] The attached diagram is labeled as follows: 1. Base; 2. Support frame; 3. Pad; 4. Sealing plate; 5. Pressure sensor; 6. Support pad; 7. Sliding column; 8. Rotary drum; 9. First swashplate; 10. Second swashplate; 11. Support rod; 12. Hinge ball; 13. Vibrating ball; 14. Air inlet; 15. Air outlet; 16. Slot; 17. Traction rod; 18. Drive motor; 19. Mounting plate; 20. Electric slide rail; 21. Mounting frame; 22. Processor; 23. Motor; 24. Lifting screw; 25. Brush seal sleeve. Detailed Implementation

[0021] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0022] Example 1 This embodiment discloses a flexible seal assembly state simulation tester, which aims to accurately simulate the assembly state, leakage characteristics, axial movement adaptability, and complex load bearing capacity of aero-engine brush seals under real working conditions. like Figure 1 , Figure 2 As shown, the flexible sealing assembly state simulation tester of this embodiment includes a base 1, which is made of Q235 steel plate by CNC machining to ensure the stability of the equipment during the test. Test components are integrated on the base 1. like Figure 1 , Figure 4 As shown, a support frame 2 is fixedly installed on the top of the base 1 by welding. The support frame 2 is made of aluminum alloy profiles and has a square frame structure. A pad 3 is provided in the middle of the support frame 2. The pad 3 is made of titanium alloy and its two ends are respectively embedded in the mounting frame 21. The outer side wall of each mounting frame 21 slides against the inner side wall of the support frame 2. An electric slide rail 20 is fixedly installed on the mounting frame 21. The electric slide rail 20 is model STH-20. Its fixed end is bolted to the side wall of the support frame 2, and its movable end is fixed to the mounting frame 21. The vertical position of the mounting frame 21 can be adjusted by the telescopic movement of the electric slide rail 20, thereby precisely adjusting the height of the pad 3. A processor 22 is embedded inside the base 1. The processor 22 is model STM32F103 and is used to receive and process the detection data of various sensors.

[0023] like Figure 1 , Figure 3 As shown, a sealing plate 4 is provided on the top of the pad 3. The sealing plate 4 is made of high-strength stainless steel and its size is adapted to the pad 3. A pressure sensor 5 is sandwiched between the pad 3 and the sealing plate 4. The pressure sensor 5 is model PT124G-210. The pressure sensor 5 is electrically connected to the processor 22 via wires to transmit pressure data in real time. Several support pads 6 are evenly distributed on the top of the pressure sensor 5. The support pads 6 are made of elastic rubber. Their bottoms are bonded and fixed to the pressure sensor 5, and their tops abut against the lower surface of the sealing plate 4. The pressure sensor 5 is provided with a sliding column 7. The sliding column 7 is a cylindrical structure. The sliding column 7 is embedded in a through hole opened in the pad 3 and is clearance-fitted with the through hole, allowing it to slide axially along the through hole.

[0024] like Figure 1 , Figure 3 As shown, a motor 23, model 57BYG250, is fixedly installed on the top of the support frame 2 by bolts. Its output end is fixedly connected to the lifting screw 24 by a coupling. A brush seal sleeve 25 is connected to the outer thread of the lifting screw 24. The bottom end of the brush seal sleeve 25 is installed at the center of the upper surface of the sealing pressure plate 4 by flange bolts. The inner thread of the brush seal sleeve 25 is precisely engaged with the outer thread of the lifting screw 24 to ensure transmission accuracy.

[0025] like Figure 1 , Figure 4 As shown, an air inlet 14 is provided on one side of the bottom of the pad 3, which is connected to an external high-temperature and high-pressure gas source through a pipe, allowing the introduction of simulated medium gas with a temperature of 200-550℃ and a pressure of 0-2MPa. An air outlet 15 is provided on one side of the top of the sealing plate 4, one end of which extends through the sealing plate 4 into the sealed cavity formed by the pad 3 and the sealing plate 4, and the other end is connected to a flow meter (not marked in the figure). The flow meter is model MF5712 and is electrically connected to the processor 22 through a wire to detect the leakage of the brush seal.

[0026] Example 2 Based on Example 1, such as Figure 1 , Figure 5 , Figure 6 , Figure 7 As shown, the test assembly also includes a rotating cylinder 8 located at the bottom of the inner cavity of the support frame 2. The rotating cylinder 8 has a cylindrical structure, and its bottom is welded and fixed to the first swashplate 9. Both the first swashplate 9 and the second swashplate 10 have a frustum-shaped structure with a cone angle of 30°. Matching ramps are respectively opened on the adjacent sides of the two swashplates, and the ramp surfaces are polished. A number of vibrating balls 13 are evenly arranged between the first swashplate 9 and the second swashplate 10. The vibrating balls 13 are made of silicon nitride ceramic and can roll between the ramps of the two swashplates.

[0027] The bottom of the second swashplate 10 has several evenly distributed support rods 11, which are made of stainless steel. Each support rod 11 has a hinge ball 12, made of carbon steel, welded to its top. Multiple hinge balls 12 extend into spherical grooves at the bottom of the second swashplate 10, fitting snugly to allow for flexible hinged operation. The bottom ends of the support rods 11 extend into grooves on the base 1, sliding along the grooves radially.

[0028] like Figure 1 , Figure 5 As shown, a drive motor 18 is coaxially mounted on the bottom of the second swashplate 10. The model of the drive motor 18 is 42BYGH47. Its output shaft is fixed to the bottom center of the second swashplate 10 by a key connection. The bottom of the drive motor 18 is fixedly mounted on the mounting plate 19. The mounting plate 19 is made of steel plate and is symmetrically mounted on the base 1 by bolts to ensure stable operation of the drive motor 18.

[0029] like Figure 8As shown, slots 16 are respectively provided on one side of the bottom of the sliding column 7 and one side of the top of the rotating drum 8. The slots 16 have a U-shaped structure. A traction rod 17 is engaged in both slots 16. The traction rod 17 is made of spring steel. Both ends of the traction rod 17 are fixed to the slots 16 by retaining springs to ensure a firm connection without loosening.

[0030] The flexible sealing assembly state simulation tester in this embodiment can simulate various real working conditions. The specific test process is as follows: Axial movement simulation test: The brush seal sample to be tested is installed between the pad 3 and the sealing pressure plate 4, covering the area of ​​the support pad 6. The motor 23 is started, driving the lifting screw 24 to rotate clockwise or counterclockwise. Since the lifting screw 24 is threadedly connected to the brush seal sleeve 25, the rotational motion is converted into axial movement of the brush seal sleeve 25, which in turn drives the sealing pressure plate 4 to move downwards or upwards. When the sealing pressure plate 4 moves downwards, it compresses the support pad 6, causing the support pad 6 to deform under force and transmit pressure to the pressure sensor 5. The pressure sensor 5 transmits the pressure signal to the processor 22, displaying the pressure value in real time. Simultaneously, the pad 3 undergoes slight deformation under pressure, further compressing the support pad 6 and causing the sliding column 7 to slide axially along the through hole of the pad 3, thus simulating the axial movement of the brush seal under real working conditions. The movement distance can be precisely controlled by the speed and number of rotations of the motor 23.

[0031] Leakage characteristic simulation test: Simultaneously with the axial movement simulation, high-temperature and high-pressure gas is introduced into the sealed cavity formed by the gasket 3 and the sealing pressure plate 4 through the air inlet 14. The gas temperature can be adjusted to 550℃ and the pressure to 2MPa by an external gas source device to simulate the extreme working environment of an aero-engine. At this time, a pressure difference is formed on both sides of the brush seal, and some gas leaks through the gap of the brush seal and is discharged through the outlet pipe 15. The flow meter on the outlet pipe 15 detects the flow rate of the leaking gas in real time and transmits the data to the processor 22. The processor 22 analyzes and processes the data to obtain the leakage characteristic parameters of the brush seal, realizing accurate simulation and detection of leakage characteristics.

[0032] Vibration load simulation test: The drive motor 18 is started, causing the second swashplate 10 to rotate. The vibrating ball 13 between the second swashplate 10 and the first swashplate 9 rotates and rolls under the influence of the slope, generating periodic vibrations. The vibration force is transmitted through the first swashplate 9 to the rotating drum 8, and then through the rotating drum 8 to the pad 3, ultimately acting on the brush seal to simulate the vibration load experienced by the brush seal during engine operation. The vibration frequency can be precisely controlled by adjusting the speed of the drive motor 18.

[0033] During the rotation of the second swashplate 10 driven by the drive motor 18, the slope angle of the second swashplate 10 changes periodically with the rotation. Since the slopes of the first swashplate 9 and the second swashplate 10 cooperate with each other, the angle change of the second swashplate 10 will lift or lower the first swashplate 9, realizing the up-and-down reciprocating motion of the first swashplate 9. The up-and-down displacement of the first swashplate 9 drives the rotating drum 8 to move up and down synchronously, and then transmits it to the brush seal through the pad 3, simulating the stress state of the brush seal under dynamic working conditions. This can detect the sealing performance and structural stability of the brush seal in a dynamic environment.

[0034] like Figure 8 As shown, when the first swashplate 9 moves up and down, it drives the rotating drum 8 to move synchronously. The rotating drum 8 pulls the sliding column 7 along the through hole of the pad plate 3 through the traction rod 17 in the slot 16 to make bidirectional displacement. The bidirectional displacement of the sliding column 7 is transmitted to the support pad 6, and then acts on the brush seal to simulate the bidirectional load force of the brush seal in the sealing state. The magnitude of the load force can be detected by the pressure sensor 5 to achieve accurate testing of the bidirectional load capacity of the brush seal.

[0035] 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 flexible sealing assembly state simulation tester, comprising a base (1), characterized in that: The base (1) is provided with test components; The test assembly includes a support frame (2) set on the top of the base (1), a pad (3) set in the middle of the support frame (2), a sealing plate (4) for pressurization set on the top of the pad (3), a pressure sensor (5) set between the pad (3) and the sealing plate (4), and a number of support blocks (6) set on the top of the pressure sensor (5). The support blocks (6) are squeezed by the deformation of the pad (3) under force to simulate the axial movement of the brush seal. A motor (23) is provided at the top of the support frame (2), and a lifting screw (24) is provided at the output end of the motor (23). A brush seal sleeve (25) is threaded to the outside of the lifting screw (24). The bottom end of the brush seal sleeve (25) is installed on the sealing pressure plate (4). The motor (23) drives the lifting screw (24) to rotate, and the lifting screw (24) applies a load to the sealing pressure plate (4) downward. The deformation of the sealing pressure plate (4) causes the support pad (6) to deform. The pressure is detected by the pressure sensor (5), thereby causing the brush seal sleeve (25) to move axially, simulating the axial movement of the brush seal. The pressure sensor (5) has a sliding column (7) at its bottom, which is embedded in the pad (3). The pad (3) has an air inlet (14) at its bottom and an exhaust pipe (15) on the sealing plate (4). High-temperature and high-pressure gas is introduced into the air inlet (14) to create a pressure difference on both sides of the brush seal. A flow meter is arranged at the exhaust pipe (15) to detect the leakage of the brush seal and simulate the leakage characteristics of the brush seal.

2. The flexible sealing assembly state simulation tester according to claim 1, characterized in that: The test assembly also includes a rotating cylinder (8) located at the bottom of the inner cavity of the support frame (2). A first swashplate (9) is located at the bottom of the rotating cylinder (8), and a second swashplate (10) is located at the bottom of the first swashplate (9). Several vibrating balls (13) are arranged between the first swashplate (9) and the second swashplate (10). When the second swashplate (10) rotates through the vibrating balls (13), the torque is transmitted to the vibrating balls (13). The vibration generated by the rotation of the vibrating balls (13) is transmitted to the first swashplate (9) to simulate the load of the brush seal being subjected to vibration.

3. The flexible sealing assembly state simulation tester according to claim 2, characterized in that: The first swashplate (9) and the second swashplate (10) are respectively provided with ramps on the adjacent side. The first swashplate (9) is lifted by rotating the second swashplate (10) to change the angle of the second swashplate (10) for dynamic testing.

4. The flexible sealing assembly state simulation tester according to claim 2, characterized in that: The bottom of the second swashplate (10) is provided with a plurality of support rods (11), and each of the support rods (11) is fixedly provided with a hinge ball (12) at the top. The plurality of hinge balls (12) extend to the bottom of the second swashplate (10) and are hinged to the second swashplate (10).

5. The flexible sealing assembly state simulation tester according to claim 4, characterized in that: The bottom of the second swashplate (10) is provided with a drive motor (18) for driving the second swashplate (10) to rotate. The bottom of the drive motor (18) is provided with a mounting plate (19). The mounting plate (19) is mounted on the base (1) by bolts. The bottom end of the support rod (11) extends to the base (1) and is slidably connected to the base (1). The second swashplate (10) is driven to rotate by the drive motor (18) so that the tilt angle of the second swashplate (10) changes, forcing the first swashplate (9) to be lifted and lowered by force.

6. The flexible sealing assembly state simulation tester according to claim 2, characterized in that: The bottom side of the slide column (7) and the top side of the rotating drum (8) are respectively provided with slots (16), and each of the two slots (16) is provided with a traction rod (17). The first swash plate (9) moves up and down, driving the rotating drum (8) to pull the traction rod (17) to move, and then driving the slide column (7) to move, which is used to simulate bidirectional load under the brush seal state.

7. The flexible sealing assembly state simulation tester according to claim 1, characterized in that: The pad (3) is provided with mounting frames (21) at both ends, and each mounting frame (21) is provided with an electric slide rail (20). The position of the mounting frame (21) is adjusted by the electric slide rail (20), thereby adjusting the height of the pad (3). The base (1) is embedded with a processor (22).

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