An engine high-speed electric lead device working condition simulation test system and method

Abstract

This invention provides a simulation test system and method for high-speed engine siphon operating conditions. The test system includes a test platform, a transmission module, a simulated engine rotor runout module, a siphon heating module, a control module, and a test module. The test module includes leads, a standard constant current source, and a voltage measurement module. It detects the electrical noise of each channel of the high-speed siphon rotor during rotation. The test method involves shorting each pair of channels to be tested at the rotating end of the high-speed siphon, and connecting the two shorted channels to the voltage measurement module at the static end to form a complete measurement loop. The reliability of the channels is evaluated by monitoring the voltage stability of this loop during rotation. By simulating rotor runout and high-temperature environment during aero-engine testing, the signal transmission stability of the high-speed siphon during use is verified, meeting the requirements for high-speed siphon signal transmission performance verification in aero-engine testing scenarios.

Description

Technical Field

[0001] This invention relates to the field of high-speed ignition circuit testing technology, and in particular to a simulation testing system and method for high-speed engine ignition circuit operating conditions. Background Technology

[0002] High-speed conductors are a special type of connector that can reliably transmit sensor signals from the rotor of a high-speed rotating component to the stator. They are widely used in the acquisition of dynamic stress, temperature, and vibration signals during the testing of aircraft engines, gas turbines, and high-speed motors, and can operate at speeds up to 50,000 rpm.

[0003] Typically, during engine testing, the engine rotor will exhibit a certain degree of radial runout. This runout is caused by rotor imbalance, unstable combustion, and other factors during engine operation, and is a key phenomenon to monitor during engine testing. During testing, the engine rotor is mechanically connected to the high-speed traction device rotor via a hexagonal coupling. The runout generated by the engine rotor is transmitted to the high-speed traction device through the shaft system. Furthermore, the external temperature of the high-speed traction device can reach 80-120°C in the engine testing environment. To ensure the reliability of the high-speed traction device's transmission, it is necessary to monitor the electrical noise generated by the traction device under high speed, high temperature, and rotor runout conditions.

[0004] The shortcomings and deficiencies of existing technologies: Currently, high-speed ignition coil testing systems can only drive the ignition coil to rotate, and cannot simulate the high speed, high temperature, and rotor runout conditions faced by the high-speed ignition coil during engine testing, nor can they verify the signal transmission reliability of the high-speed ignition coil under extreme engine testing conditions. Summary of the Invention

[0005] This invention provides a simulation test system and method for high-speed engine siphon operating conditions, which solves the problem that existing high-speed siphon test systems cannot simulate the thermal environment and rotor runout of high-speed engines, thus making it impossible to verify the reliability of signal transmission under extreme operating conditions.

[0006] In a first aspect, the present invention provides a simulation test system for the operating conditions of a high-speed engine siphon, comprising a test system platform, a transmission module, a simulated engine rotor runout module, a siphon heating module, a control module, and a test module. The test module includes leads, a standard constant current source, and a voltage measurement module, which detects the electrical noise of each channel during the rotation of the high-speed siphon rotor; it includes a dynamic signal excitation source with at least 16 channels, capable of simultaneously generating various test signals such as sine waves, square waves, and random noise; the acquisition card has 24-bit resolution and synchronous sampling function, with a synchronization error between channels ≤1µs.

[0007] The test method is as follows: short-circuit the channels under test in pairs at the rotating end of the high-speed conductor, and connect the two short-circuited channels to the voltage measurement module at the static end to form a complete measurement circuit. The reliability of the channels is evaluated by monitoring the voltage stability of this circuit during rotation.

[0008] Furthermore, the test system platform includes an integrated module compartment, a display screen, an engine environment simulation compartment, pipeline inlets and outlets, an electric spindle cooling exhaust port, casters, and an electric spindle cooling compartment. Casters are provided at the bottom of the platform for movement and fixation.

[0009] Furthermore, the transmission module includes a high-speed electric spindle, a hexagonal coupling, and a fixed platform. The high-speed electric spindle is fixed on the fixed platform and drives the high-speed actuator to achieve rotor rotation at a speed of 0~50000rpm through the hexagonal coupling.

[0010] Furthermore, the simulated engine rotor runout module includes two linear guide rails, a ball screw, a stepper motor, a lifting platform, and an electric actuator mounting base; The high-speed actuator is fixed to the lifting platform via the actuator mounting base. The lifting platform is mounted on the linear guide rail via the guide rail slider. The stepper motor drives the ball screw to drive the screw slider, controlling the lifting platform to reciprocate in the vertical direction to simulate the rotor runout of 0~30Hz and 0~1mm stroke.

[0011] Furthermore, the heating module of the high-speed electric conductor includes a heating module, an electric conductor insulation box, and a temperature sensor; the heating module heats the outside of the high-speed electric conductor, the temperature sensor monitors the outer surface temperature of the electric conductor in real time, and a non-contact labyrinth seal is used between the electric conductor insulation box and the hexagonal coupling, with the labyrinth seal reserved for the jumping gap of the lifting platform.

[0012] Furthermore, the control module includes a temperature sensor, a controller, and a host computer. The temperature sensor collects temperature data from the high-speed actuator. The controller drives the high-speed electric spindle, stepper motor, and heating module according to preset rotational speed, vibration frequency, and amplitude. The host computer provides a human-machine interface for parameter setting, status monitoring, and fault diagnosis, and has a built-in database of typical engine operating conditions, including speed spectra, vibration spectra, and temperature spectra for different engine models. During testing, preset operating conditions or custom combinations of operating conditions are invoked to achieve coordinated control of rotor vibration, rotational speed, and temperature.

[0013] Furthermore, a labyrinth seal is provided between the hexagonal coupling and the insulated box of the electric current generator. The labyrinth seal is a non-contact structure and has a reserved gap for the jumping of the lifting platform.

[0014] Secondly, the present invention provides a method for simulating the operating conditions of a high-speed engine siphon, applied to the engine high-speed siphon operating condition simulation test system described above, comprising the following steps: S1. Installation and Calibration: Install the high-speed lead under test on the test lead mounting unit, short-circuit the two channels under test in the rotating section of the high-speed lead, and connect the two short-circuited channels to the voltage measurement module in the static section to form a measurement circuit. S2. Static parameter test: Under static conditions, measure the contact resistance, insulation resistance and dielectric strength of each channel of the conductor; S3. Single-factor influence test: Start the electric spindle drive unit to make the spindle run in a stepped manner, and record the changes in signal transmission quality at different speeds; S4. Vibration effect test: Start the engine rotor runout module, apply the vibration spectrum, and test the signal stability of the ignition device under vibration environment; S5. Temperature Cycling Test: Start the environmental simulation unit and perform temperature cycling according to typical temperatures to test the impact of temperature changes on signal transmission. S6. Comprehensive Environmental Test: By setting the speed, vibration frequency, amplitude and temperature parameters through the control module, the high-speed electric spindle is started to drive the high-speed traction motor rotor to rotate, and the stepper motor is started simultaneously to simulate the vibration of the engine rotor. The heating module is started to heat to the set temperature to simulate the real working state of the engine and conduct a long-term durability test. S7. Data Analysis and Evaluation: Collect test data throughout the entire process and calculate key performance indicators.

[0015] A high-precision standard constant current source is used as the excitation source. The voltage stability of the circuit under rotation is monitored by a voltage measurement module. The electrical connection reliability of the high-speed conductor channel is evaluated based on the voltage stability.

[0016] Furthermore, in step S3, the step-by-step speed increase method is as follows: starting from 1000 rpm, the speed is increased in increments of 5000 rpm to the maximum speed, and each speed level is run stably for 5 minutes; during the test, the signal amplitude attenuation, phase drift and signal-to-noise ratio changes are monitored and recorded in real time.

[0017] Furthermore, in step S6, during the comprehensive environmental test, various extreme working conditions that may occur in actual use are applied in a concentrated manner, and the test time is not less than 100 hours; during the test, a comprehensive performance test is conducted every 4 hours, and the performance degradation trend is recorded.

[0018] The above-described technical solution of the present invention has the following advantages: This invention provides a high-speed engine ignition circuit operating condition simulation test system and method. It integrates a transmission module, a rotor runout simulation module, an environmental heating module, a control module, and a test module to verify the reliability of signal transmission under extreme operating conditions of an aero-engine. The system uses a high-speed electric spindle to drive rotor rotation, with a transmission system formed by a hexagonal coupling and a protective plate. A lifting platform composed of linear guides, ball screws, and stepper motors simulates rotor runout at a frequency of 0-30Hz and a stroke of 0-1mm. A high-temperature environment of 80-120℃ is constructed using a heating module and a labyrinth-sealed insulation chamber, with closed-loop temperature control achieved using a temperature sensor. The test module uses a high-precision constant current source excitation and voltage measurement circuit. By shorting the ignition circuit channels in pairs and monitoring the voltage stability during rotation, combined with the coordinated control of speed, runout parameters, and temperature by the host computer, it synchronously simulates the thermal environment and mechanical vibration of the engine under operating conditions of 0-50000rpm, effectively verifying the signal transmission stability and electrical connection reliability of the high-speed ignition circuit in the complex test environment of an aero-engine. Attached Figure Description

[0019] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the external appearance of the test system provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of an engine environment simulation platform provided in an embodiment of the present invention; Figure 3 A schematic diagram of the labyrinth sealing structure provided in an embodiment of the present invention; Figure 4 This is a test schematic diagram provided for an embodiment of the present invention.

[0021] Attached reference numerals: 1-Test module compartment, 2-Display screen, 3-Engine environment simulation compartment, 4-Pipeline inlet / outlet, 5-Electric spindle cooling exhaust port, 6-Fuma wheel, 7-Electric spindle cooling compartment, 8-High-speed electric spindle, 9-Electric spindle fixing fixture, 10-Fixed platform, 11-Lifting platform, 12-Insulation box, 13-Stepper motor, 14-Ball screw, 15-Screw slider, 16-Guide rail slider, 17-Linear guide rail, 18-Hexagonal coupling, 19-Labyrinth seal, 20-Electric actuator mounting base, 21-High-speed electric actuator, 22-Temperature sensor, 23-Heating module. Detailed Implementation

[0022] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of the invention. However, those skilled in the art will understand that the invention can be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, devices, circuits, and methods are omitted so as not to obscure the description of the invention with unnecessary detail.

[0023] It should be understood that, when used in this specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0024] Furthermore, in the description of this invention and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0025] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of the invention include a particular feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized. "A plurality" means "two or more."

[0026] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0027] This invention provides a simulation test system and method for high-speed ignition coil operating conditions of an engine, which mainly consists of a test system platform, a transmission module, a simulated engine rotor runout module, an ignition coil heating module, a control module, and a test module.

[0028] like Figures 1 to 3 As shown, the test system platform consists of a test module compartment [1], a display screen [2], an engine environment simulation compartment [3], pipeline inlet and outlet [4], an electric spindle cooling exhaust port [5], a fan wheel [6], and an electric spindle cooling chamber [7]. The test system is integrated into one platform, which can be moved by the fan wheel at the bottom. After the movement is completed, the fan wheel is locked and fixed in place.

[0029] The transmission module consists of a high-speed electric spindle [8], a hexagonal coupling

[18] , and a fixed platform

[10] . The high-speed electric spindle is fixed on the fixed platform

[10] and drives the rotor of the high-speed traction device

[21] to rotate through the hexagonal coupling

[18] .

[0030] The simulated engine rotor runout module consists of two linear guide rails

[17] , a ball screw

[14] , a stepper motor

[13] , a lifting platform

[11] , and an actuator mounting base

[20] . The high-speed actuator

[21] is fixed on the lifting platform

[11] through the actuator mounting base

[20] . The lifting platform

[11] is fixed on the linear guide rail

[17] through the guide rail slider

[16] . Only vertical movement is allowed. The stepper motor

[13] , the ball screw

[14] , and the screw slider

[15] control the vertical reciprocating movement of the lifting platform

[11] . It can simulate the rotor runout of the engine rotor at a frequency of 0~30Hz and a stroke of 0~1mm, and accurately reproduce the engine rotor runout condition.

[0031] The heating module of the electric conductor consists of a heating module

[23] , an electric conductor insulation box

[12] , and a temperature sensor

[22] . The heating module

[23] heats the outside of the high-speed electric conductor, and the temperature sensor

[22] monitors the temperature of the outer surface of the electric conductor in real time. The electric conductor insulation box

[12] and the hexagonal coupling

[18] adopt a non-contact labyrinth seal

[19] to ensure that the temperature inside the insulation box is stable at 80~120℃. The labyrinth seal

[19] reserves the gap for the jumping of the lifting platform to ensure that no friction occurs.

[0032] The control module consists of a temperature sensor, a controller, and a host computer. The control module is composed of a temperature sensor, a programmable controller, and a host computer system. It achieves precise adjustment of test parameters through closed-loop control. The temperature sensor collects high-speed actuator and ambient temperature data in real time. The controller coordinates the drive of the high-speed electric spindle [8], stepper motor

[13] , and heating module

[23] according to the preset speed, jumping frequency, and amplitude parameters to ensure that all actuators operate synchronously. The host computer provides a human-machine interface, supports parameter setting, status monitoring, and fault diagnosis. Through dynamic adjustment of control commands, it achieves multi-dimensional coordinated control of rotor jumping, speed, and temperature conditions, ensuring the stability and reliability of the test process.

[0033] The test module consists of leads, a standard constant current source, and a voltage measurement module, which detects the electrical noise of each channel during the rotation of the high-speed lead rotor.

[0034] like Figure 4As shown, the test method is as follows: The channels under test are shorted in pairs at the rotating end of the high-speed conductor, and the two shorted channels are connected to the voltage measurement module at the static end to form a complete measurement loop. The reliability of the channels is evaluated by monitoring the voltage stability of this loop during rotation. To ensure the electrical connection reliability of the high-speed conductor channels, a high-precision standard constant current source is introduced as the excitation. A high-precision, low-noise, and low-temperature drift DC current reference source is selected.

[0035] By simulating rotor runout and high-temperature environment during the testing process of an aero-engine, the signal transmission stability of the high-speed ignition device during use is verified, which meets the requirements for verifying the signal transmission performance of the high-speed ignition device under aero-engine testing scenarios.

[0036] A simulation testing system and method for high-speed engine actuator operating conditions comprises an electric spindle, frequency converter, speed sensor, temperature sensor, lifting platform, fixed platform, actuator mounting base, guide rail, ball screw, stepper motor, heating module, insulation box, protective cover, constant current source, and voltage measurement module. This invention can simultaneously simulate the rotor runout of an engine rotor at a frequency of 0-30Hz and a stroke of 0-1mm, and an ambient temperature of 80-120℃ during high-speed actuator rotation testing from 0 to 50000 rpm.

[0037] The high-speed traction power supply rotor is powered by an electric spindle, which is flexibly connected to the traction power supply rotor via a hexagonal coupling. The electric spindle uses high-speed ceramic ball bearings to avoid using oil mist lubrication to cool the bearings, thus preventing contamination of the table and the high-speed traction power supply. The lifting platform is fixed with guide rails and uses ball screws to move up and down, simulating the vibration of an engine rotor. A stepper motor is used as the power source for the lifting platform to ensure a frequency of 0~30Hz and a stroke accuracy of 0~1mm.

[0038] The electric spindle is fixed to a fixed platform, and the conductor is fixed to a lifting platform. The insulation box encloses the conductor, and the temperature inside the insulation box is controlled at 80~120℃ by a heating module. The insulation box has a built-in thermal resistor for temperature control. A labyrinth seal is used between the insulation box and the hexagonal coupling to prevent friction between the coupling and the insulation box. The protective cover has reserved channels for cooling pipes, circuits, and leads, and has the functions of protecting the high-speed rotor from falling off and eliminating noise.

[0039] The test method is as follows: short-circuit the rotor circuit of the high-speed energizer, apply a constant current to the test circuit, monitor the change in circuit voltage, and the result is electrical noise.

[0040] The beneficial effects of this invention are as follows: A high-speed siphon test system was designed to synchronously simulate rotor runout and ambient high temperature. It can synchronously simulate rotor runout with a frequency of 0~30Hz and a stroke of 0~1mm and an ambient high temperature of 80~120℃ during the test of aero-engines at high speeds of 0~50000rpm, effectively verifying the reliability of the high-speed siphon under extreme conditions.

[0041] It should be noted that the various embodiments in this specification are described in a progressive manner, and the same or similar parts between the various embodiments can be referred to mutually. Each embodiment focuses on describing the differences from other embodiments. The present invention is not limited to the specific structures described above and shown in the figures. Furthermore, for the sake of brevity, detailed descriptions of known methods and techniques are omitted here.

[0042] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention, and should all be included within the protection scope of the present invention.

Claims

1. A simulation test system for high-speed engine ignition circuit conditions, characterized in that, The system includes a test platform, a transmission module, a simulated engine rotor vibration module, a lead heater module, a control module, and a test module. The test module includes leads, a standard constant current source, and a voltage measurement module, which detects the electrical noise of each channel during the rotation of the high-speed lead rotor. The test method is as follows: short-circuit the channels under test in pairs at the rotating end of the high-speed conductor, and connect the two short-circuited channels to the voltage measurement module at the static end to form a complete measurement circuit. The reliability of the channels is evaluated by monitoring the voltage stability of this circuit during rotation.

2. The engine high-speed ignition circuit condition simulation test system according to claim 1, characterized in that, The test system platform includes an integrated module compartment, a display screen, an engine environment simulation compartment, pipeline inlets and outlets, an electric spindle cooling exhaust port, casters, and an electric spindle cooling compartment. Casters are provided at the bottom of the platform for movement and fixation.

3. The engine high-speed ignition circuit condition simulation test system according to claim 1, characterized in that, The transmission module includes a high-speed electric spindle, a hexagonal coupling, and a fixed platform. The high-speed electric spindle is fixed on the fixed platform and drives the high-speed actuator to achieve rotor rotation at speeds of 0 to 50,000 rpm through the hexagonal coupling.

4. The engine high-speed ignition circuit condition simulation test system according to claim 1, characterized in that, The simulated engine rotor runout module includes two linear guide rails, a ball screw, a stepper motor, a lifting platform, and an electric actuator mounting base; The high-speed actuator is fixed to the lifting platform via the actuator mounting base. The lifting platform is mounted on the linear guide rail via the guide rail slider. The stepper motor drives the ball screw to drive the screw slider, controlling the lifting platform to reciprocate in the vertical direction to simulate the rotor runout of 0~30Hz and 0~1mm stroke.

5. The engine high-speed ignition circuit condition simulation test system according to claim 3, characterized in that, The heating module of the high-speed conductor includes a heating module, a conductor insulation box, and a temperature sensor. The heating module heats the outside of the high-speed conductor, and the temperature sensor monitors the outer surface temperature of the conductor in real time. The conductor insulation box and the hexagonal coupling adopt a non-contact labyrinth seal, and the labyrinth seal is reserved for the jumping gap of the lifting platform.

6. The engine high-speed ignition circuit condition simulation test system according to claim 1, characterized in that, The control module includes a temperature sensor, a controller, and a host computer; the temperature sensor collects temperature data from the high-speed actuator; the controller drives the high-speed electric spindle, stepper motor, and heating module according to preset rotation speed, fluctuation frequency, and amplitude; the host computer provides a human-machine interface for parameter setting, status monitoring, and fault diagnosis, and has a built-in database of typical engine operating conditions.

7. The engine high-speed traction device operating condition simulation test system according to claim 5, characterized in that, A labyrinth seal is provided between the hexagonal coupling and the insulated box of the electric current generator. The labyrinth seal is a non-contact structure and is designed to allow for the jumping gap of the lifting platform.

8. A method for simulating the operating conditions of a high-speed engine siphon, applied to the engine high-speed siphon operating condition simulation test system according to any one of claims 1 to 7, characterized in that, Includes the following steps: S1. Installation and Calibration: Install the high-speed lead under test on the test lead mounting unit, short-circuit the two channels under test in the rotating section of the high-speed lead, and connect the two short-circuited channels to the voltage measurement module in the static section to form a measurement circuit. S2. Static parameter test: Under static conditions, measure the contact resistance, insulation resistance and dielectric strength of each channel of the conductor; S3. Single-factor influence test: Start the electric spindle drive unit to make the spindle run in a stepped manner, and record the changes in signal transmission quality at different speeds; S4. Vibration effect test: Start the engine rotor runout module, apply the vibration spectrum, and test the signal stability of the ignition device under vibration environment; S5. Temperature Cycling Test: Start the environmental simulation unit and perform temperature cycling according to typical temperatures to test the impact of temperature changes on signal transmission. S6. Comprehensive Environmental Test: By setting the speed, vibration frequency, amplitude and temperature parameters through the control module, the high-speed electric spindle is started to drive the high-speed traction motor rotor to rotate, and the stepper motor is started simultaneously to simulate the vibration of the engine rotor. The heating module is started to heat to the set temperature to simulate the real working state of the engine and conduct a long-term durability test. S7. Data Analysis and Evaluation: Collect test data throughout the entire process and calculate key performance indicators.

9. The method for simulating the operating conditions of a high-speed engine ignition coil according to claim 8, characterized in that, In step S3, the step-by-step speed increase method is as follows: starting from 1000 rpm, the speed is increased in increments of 5000 rpm to the maximum speed, and each speed level is run stably for 5 minutes; during the test, the signal amplitude attenuation, phase drift and signal-to-noise ratio changes are monitored and recorded in real time.

10. The method for simulating the operating conditions of a high-speed engine ignition coil according to claim 8, characterized in that, In step S6, during the comprehensive environmental test, various extreme working conditions that may occur in actual use are applied in a concentrated manner, and the test time is not less than 100 hours. During the test, a comprehensive performance test is conducted every 4 hours, and the performance degradation trend is recorded.

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