A high-precision power measurement method for aero-engine test

Abstract

This application provides a high-precision power measurement method for aero-engine testing, belonging to the field of aero-engine technology. It includes a test bench main body comprising a drive unit, a dynamometer, a torque transducer, a test bench output shaft, and a turbine under test. The torque transducer is located on the turbine output shaft side. The zero point of the torque transducer is calibrated. Before installing the turbine under test, the torque transducer is statically calibrated. The drive unit is used to dynamically calibrate the test bench shaft system, obtaining the torque versus speed function of the torque transducer under no-load conditions on the test bench. The drive unit is disconnected, the turbine under test is installed, and the zero point of the torque transducer is recalibrated. The torque transducer is then statically calibrated again. A power measurement test of the turbine under test is conducted. Based on the test speed and the aforementioned function during the test, the torque measured by the torque transducer is corrected, and the turbine output power is obtained based on a preset conversion rule. This application reduces the impact of system errors on the measurement results, achieving accurate measurement of the turbine component shaft power across the entire operating range.

Description

Technical Field

[0001] This application relates to the field of aero-engine technology, and in particular to a high-precision power measurement method for aero-engine testing. Background Technology

[0002] A turbine is a rotating mechanical device that converts the internal energy of a fluid into mechanical energy. In aero-engines such as gas turbines, gas turbines, and turboshaft engines, the turbine serves as a core power-generating component. Its development requires extensive physical testing to obtain the turbine component or engine's performance, with output power being one of the core indicators. During testing, a dynamometer or torque meter is used to measure the output torque at the turbine or engine's output shaft during operation, and this torque is combined with the measured rotational speed to calculate the turbine or turboshaft engine's output power. Because atmospheric conditions vary greatly at different flight altitudes during aero-engine operation, the range of turbine output power is extremely wide, sometimes exceeding 20 times at the same rotational speed. Therefore, the broad torque measurement requirements for turbine components place new demands on calibration methods.

[0003] As a power output device, the primary purpose of testing turbine components is to measure their output power. This process requires consuming the shaft power they output. The instruments used to measure and absorb this power are called dynamometers or dynamometer machines, typically hydraulic dynamometers. For turbine component tests requiring full-range height conditions, the power variation range is large, and existing power measurement methods cannot guarantee measurement accuracy across the entire test range. For ease of understanding, [further details are needed]. Figure 1 Two typical turbine test bench main structures are presented. While existing dynamometers utilize force sensors with high measurement accuracy, in practical applications, the long force transmission path from the turbine to the dynamometer and the numerous influencing factors necessitate calibration or standardization of torque measurements before testing to ensure accurate power measurement. Due to shaft system limitations, existing methods perform static calibration of the force sensor before connecting the turbine and dynamometer system, followed by installation of the shaft coupling for testing. Existing methods cannot accurately assess the additional torque caused by factors such as torque measurement, installation, lubrication, friction, and wind resistance. For turbine components with a wide operating range, power variations can range from thousands of kilowatts to tens of kilowatts, corresponding to torques ranging from thousands to tens of Newton-meters. The additional torque and the dynamic characteristics of the test shaft system significantly affect low-torque conditions, causing significant distortion in measurement results and preventing the acquisition of the turbine component's true operating characteristics. Summary of the Invention

[0004] In view of this, embodiments of this application provide a high-precision power measurement method for aero-engine testing, so as to achieve accurate measurement of the output power of aero-engine turbine components with a wide power output range and reduce the output power measurement error.

[0005] This application provides a high-precision power measurement method for aero-engine testing, including:

[0006] The main body of the test bench is configured, including a drive unit, a dynamometer, a torque meter, the test bench output shaft and the turbine under test connected in sequence. The torque meter is located on the turbine output shaft side of the turbine under test, and the zero point of the torque meter is verified. Before installing the turbine under test, the torque meter was statically calibrated. Before installing the turbine under test, the shaft system of the test bench is dynamically calibrated using a drive device to obtain the torque as a function of rotational speed measured by the torque meter under no-load conditions on the test bench. Disconnect the drive unit, install the turbine under test, and recalibrate the zero point of the torque meter; Recalibrate the torque meter statically; A power measurement test is conducted on the turbine under test. Based on the test state speed and the torque as a function of speed, the torque measured by the torque meter is corrected, and the turbine output power is obtained based on a preset conversion rule.

[0007] According to one specific implementation of the present application, the torque tester is located at the input shaft end of the dynamometer, and the output shaft end of the dynamometer is connected to the output shaft of the drive device.

[0008] According to a specific implementation of an embodiment of this application, the static calibration of the torque meter includes: Connects the output shaft of the drive unit, the shaft of the dynamometer, and the output shaft of the test bench; Installing a shaft locking device reliably locks the entire shaft system, preventing the shaft from rotating. The shaft locking device does not generate additional torque on the torque meter. Install the calibration arm and level it by adjusting the counterweight slider so that the torque meter's measurement value is zero. The torque meter was calibrated using a standard source, and the shaft locking device and calibration arm were removed.

[0009] According to a specific implementation of an embodiment of this application, the step of dynamically calibrating the shaft system of the test bench using a driving device to obtain the torque as a function of rotational speed measured by the torque meter under no-load conditions on the test bench includes: The machine is driven to rotate at a constant speed to the rated speed of the test bench, and then rotated at a constant speed to stop. During the operation, the torque and speed of the torque meter are continuously recorded to obtain the torque as a function of speed.

[0010] According to a specific implementation of an embodiment of this application, the expression of the preset conversion rule is: , Where P is the turbine output power, T0 is the torque measured by the torque meter in the power measurement test, n is the test speed, and T d The torque is the torque corresponding to the test rotational speed in the function.

[0011] According to a specific implementation of an embodiment of this application, the verification of the zero point of the torque meter includes: Adjust the torque meter reading to zero when the torque is in a true zero-torque state.

[0012] According to one specific implementation of the embodiments of this application, the dynamometer is a hydraulic dynamometer, an air-type dynamometer, or an electric dynamometer.

[0013] According to one specific implementation of an embodiment of this application, the driving device is configured as a high-speed variable frequency motor.

[0014] According to one specific implementation of the embodiments of this application, the range of the torque measuring device meets the requirements of the entire test condition range.

[0015] Beneficial effects: Systematic errors caused by mechanical transmission, lubrication, and friction increase significantly with increasing rotational speed. While these systematic errors have a minor impact on the performance analysis of conventional high-power turbine components, they can lead to significant measurement errors and severe distortion of overall performance characteristics for turbine components operating across a wide power range, from several thousand kilowatts to tens of kilowatts. This method improves upon existing turbine component performance testing methods by conducting dynamic characteristic tests on the test bench before conventional turbine characteristic tests to obtain the dynamic characteristics of the test component (excluding the turbine under test). During turbine component performance testing, the dynamic characteristics of the test bench are used to correct the test results across the entire range. This significantly reduces the impact of systematic errors on measurement results, enabling accurate measurement of the shaft power of aero-engine turbine components across the entire operating range of the test bench, thereby obtaining complete performance data for turbine components with a wide operating speed and power range. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 The diagram shows the main structure of a turbine test bench in the prior art. (a) shows the dynamometer directly connected to the test turbine, and (b) shows the dynamometer connected to the turbine through a gearbox. Figure 2 This is a schematic diagram of the main structure of a turbine test bench according to an embodiment of the present invention; Figure 3 This is a flowchart of a high-precision power measurement method for aero-engine testing according to an embodiment of the present invention; Figure 4 This is a schematic diagram illustrating torque as a function of rotational speed according to an embodiment of the present invention.

[0018] In the diagram: 1. Test turbine; 2. Dynamometer; 3. Gearbox; 4. Torque meter; 5. Drive unit; A. Compressed airflow; Z1. Turbine output shaft; Z2. Test bench output shaft; Z3. Dynamometer shaft; Z4. Drive unit output shaft. Detailed Implementation

[0019] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0020] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. This application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0021] It should be noted that various aspects of embodiments within the scope of the appended claims are described below. It will be apparent that the aspects described herein can be embodied in a wide variety of forms, and any particular structure and / or function described herein is merely illustrative. Based on this application, those skilled in the art will understand that one aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number of aspects set forth herein can be used to implement the device and / or practice the method. Additionally, this device and / or method can be implemented using structures and / or functionalities other than one or more of the aspects set forth herein.

[0022] It should also be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this application. The illustrations only show the components related to this application and are not drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0023] Furthermore, specific details are provided in the following description to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that the described aspects can be practiced without these specific details.

[0024] This application provides a high-precision power measurement method for aero-engine testing, including the following steps: Step S01: Configure the main body of the test bench, including the drive device 5, dynamometer 2, torque meter 4, test bench output shaft Z2 and the turbine under test 1 connected in sequence. The torque meter 4 is located on the turbine output shaft Z1 side of the turbine under test 1. Verify the zero point of the torque meter 4. Step S02: Before installing the turbine under test 1, perform static calibration on the torque meter 4; Step S03: Before installing the turbine under test 1 (connect the output shaft Z4 of the drive device, the shaft Z3 of the dynamometer, and the output shaft Z2 of the test bench, without installing the turbine under test 1), use the drive device 5 to dynamically calibrate the shaft system of the test bench, and obtain the torque measured by the torque meter 4 under the no-load condition of the test bench as a function of the rotational speed (i.e., the dynamic characteristics of the test bench). Step S04: Disconnect the drive unit 5 (disconnect the drive unit output shaft Z4 from the dynamometer shaft Z3), install the turbine under test 1 (connect the test bench output shaft Z2 from the turbine output shaft Z1), and recalibrate the zero point of the torque meter 4. Step S05: Recalibrate the torque meter 4 statically; Step S06: Conduct a power measurement test on the turbine under test 1. Based on the test state speed and the torque as a function of speed, correct the torque measured by the torque meter 4, and obtain the turbine output power based on the preset conversion rule.

[0025] In this embodiment, dynamic characteristic tests of the test bench are conducted before conventional turbine characteristic tests to obtain the dynamic characteristics of the test bench, excluding the turbine under test 1. When performing turbine component performance tests, the dynamic characteristics of the test bench are used to correct the test results across the entire range, which can significantly reduce the impact of system errors on the measurement results and achieve accurate measurement of the shaft power of the aero-engine turbine component within the full working range of the test bench, thereby obtaining complete performance data of the turbine component with a wide speed and power working range.

[0026] In one embodiment, the torque meter 4 is located at the input shaft end of the dynamometer 2, and the output shaft end of the dynamometer 2 is connected to the output shaft Z4 of the drive device.

[0027] Specifically, the main structure of the turbine test bench used in this embodiment refers to... Figure 2 The drive unit 5, dynamometer 2, torque meter 4, test bench output shaft Z2 and the turbine under test 1 are connected in sequence. Torque meter 4, whose accuracy and range meet the requirements of the entire test working condition range, is installed at the input shaft end of dynamometer 2.

[0028] In one embodiment, the static calibration of the torque meter 4 includes: Connect the output shaft Z4 of the drive unit, the shaft Z3 of the dynamometer, and the output shaft Z2 of the test bench; The shaft locking device is installed to reliably lock the entire shaft system, preventing the shaft from rotating. The shaft locking device does not generate additional torque on the torque meter 4. Install the calibration arm and level it by adjusting the counterweight slider so that the measurement value of the torque meter 4 is zero. Static calibration of torque meter 4 was performed using a standard source (weights), and the shaft locking device and calibration arm were removed.

[0029] In one embodiment, the step of dynamically calibrating the shaft system of the test bench using the drive device 5 to obtain the torque as a function of rotational speed measured by the torque meter 4 under no-load conditions on the test bench includes: The drive device 5 is used to uniformly increase the speed to the rated speed of the test bench and then uniformly decrease the speed to stop. During the operation, the torque and speed of the torque measuring device 4 are continuously recorded to obtain the torque as a function of speed.

[0030] According to a specific implementation of an embodiment of this application, the expression of the preset conversion rule is: , Where P is the turbine output power, T0 is the torque measured by torque meter 4 in the power measurement test, n is the test speed, and T d The torque is the torque corresponding to the test rotational speed in the function.

[0031] In one embodiment, the zero point calibration of the torque meter 4 includes: Adjust the torque meter 4 to zero when the torque is in a true zero-torque state.

[0032] In one embodiment, the dynamometer 2 is a hydraulic dynamometer, an air dynamometer, or an electric dynamometer.

[0033] In one embodiment, the drive device 5 is configured as a high-speed variable frequency motor.

[0034] In one embodiment, the range of the torque meter 4 meets the requirements of the entire test condition range.

[0035] The method of this application is described below with reference to a specific embodiment, which includes the following steps: Step S11, Press Figure 2The main body of the test bench is configured. The dynamometer 2 is a hydraulic dynamometer, and the drive device 5 is a high-speed variable frequency motor. A torque tester 4 with accuracy and range that meet the requirements of the entire test working condition range is installed at the input shaft end of the dynamometer 2, and the zero point of the torque tester 4 is calibrated (that is, the measured value of the torque tester 4 is adjusted to 0 when there is no torque). Step S12: Connect the output shaft Z4 of the drive unit, the dynamometer shaft Z3, and the output shaft Z2 of the test bench. Do not install the turbine under test 1. Use a shaft locking device to reliably lock the entire shaft system (i.e., the shaft system composed of the output shaft Z4 of the drive unit, the dynamometer shaft Z3, and the output shaft Z2 of the test bench) so that the shaft cannot rotate. The shaft locking device should not generate additional torque on the torque tester 4. In this example, a symmetrical adjustable leveling calibration arm and standard weights are used to preload and calibrate the torque tester 4. Install the dedicated calibration arm for the torque tester 4 and level the calibration arm (i.e., adjust the measured value of the torque tester 4 to 0 by adjusting the counterweight slider). After installation, preload the torque tester 4. After preloading, use standard weights to perform static calibration on the torque tester 4. Step S13: Remove the calibration arm and shaft locking device, calibrate the zero point of the torque meter 4, and use a high-speed variable frequency motor to uniformly increase the speed to the rated speed of the test bench, then uniformly decrease the speed and stop the machine. During the operation, continuously record the torque and speed of the torque meter 4 to obtain the torque variation function with speed. Its curve is as follows Figure 4 ; Step S14: Install the test turbine 1 (i.e., complete) Figure 2 Remove the connection between the output shaft Z1 of the turbine and the output shaft Z2 of the test bench, dismantle the drive unit 5 (i.e. disconnect the connection between the output shaft Z4 of the drive unit and the shaft Z3 of the dynamometer), and recalibrate the zero point of the torque meter 4. Step S15: Lock the test bench shaft system (i.e., the shaft system composed of turbine output shaft Z1, test bench output shaft Z2 and dynamometer shaft Z3) again and calibrate the torque meter 4 again. After calibration, remove the shaft locking device and the torque meter 4 special calibration device. Step S16: Conduct the test normally. During data processing, use the dynamic torque characteristics of the test bench according to the test state speed. The torque T0 measured by torque meter 4 is corrected according to formula 4. Calculate the turbine output power. In this example, the turbine's high speed and low power state can reduce the shaft power and efficiency measurement error by about 6%.

[0036] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A high-precision power measurement method for aero-engine testing, characterized in that, include: The main body of the test bench is configured, including a drive unit (5), a dynamometer (2), a torque meter (4), a test bench output shaft (Z2), and a turbine under test (1) connected in sequence. The torque meter (4) is located on the turbine output shaft (Z1) side of the turbine under test (1) to verify the zero point of the torque meter (4). Before installing the turbine under test (1), the torque meter (4) is statically calibrated; Before installing the turbine under test (1), the shaft system of the test bench is dynamically calibrated using the drive device (5) to obtain the torque measured by the torque meter (4) under the no-load condition of the test bench as a function of the rotational speed. Disconnect the drive unit (5), install the turbine under test (1), and recalibrate the zero point of the torque meter (4); Recalibrate the torque meter (4) statically; A power measurement test was conducted on the turbine under test (1). Based on the test state speed and the torque as a function of the speed, the torque measured by the torque meter (4) was corrected, and the turbine output power was obtained based on the preset conversion rule.

2. The high-precision power measurement method for aero-engine testing according to claim 1, characterized in that, The torque tester (4) is located at the input shaft end of the dynamometer (2), and the output shaft end of the dynamometer (2) is connected to the output shaft (Z4) of the drive device.

3. The high-precision power measurement method for aero-engine testing according to claim 1, characterized in that, The static calibration of the torque meter (4) includes: Connect the output shaft of the drive unit (Z4), the dynamometer shaft (Z3), and the output shaft of the test bench (Z2). Installing a shaft locking device reliably locks the entire shaft system, preventing the shaft from rotating. The shaft locking device does not generate additional torque on the torque meter (4). Install the calibration arm and level it by adjusting the counterweight slider so that the measurement value of the torque meter (4) is zero. The torque tester (4) was calibrated using a standard source, and the shaft locking device and calibration arm were removed.

4. The high-precision power measurement method for aero-engine testing according to claim 1, characterized in that, The method of using a drive device (5) to dynamically calibrate the shaft system of the test bench and obtain the torque as a function of rotational speed measured by the torque meter (4) under no-load conditions on the test bench includes: Using the drive device (5), the machine is rotated at a constant speed to the rated speed of the test bench and then rotated at a constant speed to stop. During the operation, the torque and speed of the torque measuring device (4) are continuously recorded to obtain the torque as a function of the speed.

5. The high-precision power measurement method for aero-engine testing according to claim 1, characterized in that, The expression for the preset conversion rule is: ， Where P is the turbine output power, T0 is the torque measured by the torque meter (4) in the power measurement test, n is the test speed, and T d The torque is the torque corresponding to the test rotational speed in the function.

6. The high-precision power measurement method for aero-engine testing according to claim 1, characterized in that, The zero point of the torque meter (4) is verified, including: Adjust the torque meter (4) to zero when the torque is in a true zero-torque state.

7. The high-precision power measurement method for aero-engine testing according to claim 1, characterized in that, The dynamometer (2) is a hydraulic dynamometer (2), an air dynamometer (2), or an electric dynamometer (2).

8. The high-precision power measurement method for aero-engine testing according to claim 1, characterized in that, The drive device (5) is configured as a high-speed variable frequency motor.

9. The high-precision power measurement method for aero-engine testing according to claim 1, characterized in that, The range of the torque measuring device (4) meets the requirements of the full test conditions.

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