A movable distributed small and medium power hybrid propulsion system ground bench test device

Abstract

The application provides a movable distributed small and medium power mixed power propulsion system ground bench test device, which comprises a reinforcing support frame, a vertical direction guide slide rail arranged on the reinforcing support frame and a height lifting adjusting block detachably sleeved outside the guide slide rail, a main body mounting support frame provided with a plurality of uniformly distributed thrust generating devices and a sliding connection between the main body mounting support frame and the reinforcing support frame. The application supports simultaneous installation and test of a plurality of power units in the system, including a fuel engine, a motor, a generator and an energy storage device, and realizes cascade test of the whole system.

Description

Technical Field

[0001] This invention relates to the field of aero-engine testing technology, specifically to a mobile distributed low-to-medium power hybrid electric propulsion system ground test bench device. Background Technology

[0002] Currently, aero-engine technology faces multiple pressures to improve thermal efficiency and reduce fuel consumption and pollutant emissions. Constrained by material properties, manufacturing processes, and structural design, relying solely on traditional technical approaches such as increasing thermodynamic cycle parameters and altering the flow distribution within and outside the engine's bypass ducts is becoming increasingly saturated and can no longer meet the stringent energy conservation and environmental protection requirements of the future aviation industry.

[0003] While all-electric propulsion represents a long-term goal for achieving zero emissions in aviation, its current limitations, stemming from energy storage technology and power density, primarily restrict its application to small and medium-sized aircraft. Hybrid power systems, as a key technological pathway from fuel-powered to all-electric propulsion, combined with a distributed propulsion layout, can significantly reduce fuel consumption and emissions while maintaining existing aviation capacity, making it one of the most feasible green aviation solutions currently available.

[0004] Existing ground test equipment for aero-engines is mainly designed for traditional gas turbine engines, which has technical limitations such as limited test objects and fixed installation methods, making it difficult to meet the testing needs of new distributed hybrid electric propulsion systems with multiple power units working together. Summary of the Invention

[0006] In view of this, the present invention provides a mobile distributed small-to-medium power hybrid electric propulsion system ground test bench to solve the problem that existing aerospace power ground test equipment is mainly designed for traditional gas turbine engines, and has technical limitations such as single test objects and fixed installation methods, making it difficult to adapt to the testing needs of multi-power unit collaborative operation of new distributed hybrid electric propulsion systems.

[0007] The present invention provides the following technical solution: a mobile distributed small-to-medium power hybrid electric propulsion system ground test device, comprising: a reinforcing support frame, fixedly connected to the ground, the reinforcing support frame being provided with vertically arranged guide rails and detachable height adjustment blocks sleeved outside the guide rails; a main mounting bracket, provided with multiple evenly distributed thrust generating devices; the main mounting bracket being slidably connected to the reinforcing support frame.

[0008] Compared with the prior art, the beneficial effects that the at least one technical solution adopted by the present invention can achieve include at least the following:

[0009] Multi-test component compatibility: Supports simultaneous installation and testing of multiple power units in the system, including fuel engines, electric motors, generators and energy storage devices, to achieve cascaded testing of the entire system; Flexible and adjustable installation method: The structural design is highly adaptable and compatible with various installation layouts and connection methods to meet the testing requirements of different propulsion systems; Modular and mobile design: The modular structure and mobile platform facilitate deployment, adjustment and site relocation, improving the utilization efficiency and applicability of the test facility. Attached Figure Description

[0010] 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.

[0011] Figure 1 This is a layout diagram of a ground test bench for a mobile, distributed, low-to-medium power hybrid electric propulsion system.

[0012] Figure 2 This is a schematic diagram of the installation and adjustment device for a movable thrust generator under vertical intake and exhaust conditions.

[0013] Figure 3 This is a schematic diagram illustrating the vertical lifting and lowering working principle of a ducted fan.

[0014] Figure 4 This is a schematic diagram of the installation device for a portable gas turbine engine, generator, and its accessories.

[0015] Figure 5 This is a schematic diagram of a portable atmospheric pressure fuel tank.

[0016] The attached diagram contains the following labels: 1. Thrust generator; 2. Movable ducted fan mounting and adjusting device; 21. Main mounting bracket; 22. Reinforcing support frame; 23. Height adjustment block; 24. Mounting guide rod; 25. Hydraulic shock absorber; 26. Movable caster wheel; 3. Gas turbine engine and generator; 4. Movable engine mounting and adjusting device; 41. Mounting bracket; 42. Generator controller; 43. Engine controller; 44. Battery storage device; 45. Mounting screws; 46. Movable caster wheel; 5. Movable oil tank; 501. Handrail; 502. Lifting lug; 503. Flip-top cleaning device; 504. Oil inlet with oil filter; 505. Sampling port / low-level oil supply port; 506. Oil drain port; 507. Caster wheel; 508. Observation hole; 509. High-level oil supply port / spare port; 510. Level gauge. Detailed Implementation

[0017] The embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0018] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0019] See Figures 1 to 5 This embodiment provides a mobile distributed small-to-medium power hybrid electric propulsion system ground test device, including a mobile ducted fan installation and adjustment device 2, a mobile engine installation and adjustment device 4, and a mobile fuel tank 5.

[0020] like Figure 1 As shown, in the layout of the ground test bench, the thrust generator 1 is supported and installed via a movable ducted fan mounting adjustment device 2; the gas turbine engine and generator 3 are supported and installed via a movable engine mounting adjustment device 4; and the movable fuel tank 5 is positioned to the side and front of the gas turbine engine and generator 3 to ensure that the fuel tank is far away from the high-temperature exhaust gas from the engine. An appropriate distance is maintained between the gas turbine engine and generator 3 and the thrust generator 1 to ensure that their respective intake and exhaust flow fields do not interfere with each other, and that the high-temperature exhaust gas generated by the gas turbine engine and generator 3 does not damage the thrust generator 1. During the test, both the movable ducted fan mounting adjustment device 2 and the movable engine mounting adjustment device 4 are securely fixed to the test site ground.

[0021] like Figure 2 , Figure 3 As shown, the movable ducted fan mounting and adjusting device 2 includes a main mounting bracket 21, a reinforcing support frame 22, a height adjustment block 23, a mounting and fixing guide rod 24, a hydraulic shock absorption device 25, and movable casters 26.

[0022] The reinforced support frame 22 is fixedly connected to the ground, and vertically arranged mounting guide rods 24 are provided on the reinforced support frame 22. The mounting guide rods 24 adopt a T-shaped design, which can achieve both fixation to the test site and reusability. Multiple height adjustment blocks 23 are detachably sleeved on the mounting guide rods 24 and arranged sequentially along the axial direction of the mounting guide rods 24 to meet different height adjustment requirements. The lower end of the reinforced support frame 22 is provided with multiple evenly spaced movable casters 26, which can realize the movement of the device and the thrust generating device 1 within the test site. The top of the reinforced support frame 22 is provided with lifting lugs to facilitate overall hoisting, and the position of the lifting lugs is set according to the center of gravity of the device.

[0023] The main mounting bracket 21 is equipped with multiple evenly spaced thrust generating devices 1; the thrust generating devices 1 are ducted fans, rotors, or propellers, and in this embodiment, ducted fans are used. The thrust generating devices 1 are installed on the main mounting bracket 21 with vertical air intake, intake from the top and exhaust from the bottom. The thrust generating devices 1 are arranged in two rows, symmetrically arranged with respect to the centerline of the main mounting bracket 21. The main mounting bracket 21 is slidably connected to the reinforcing support frame 22. The main mounting bracket 21 and the thrust generating devices 1 can move vertically up and down along the mounting guide rod 24 to simulate the scenario of vertical takeoff of the thrust generating devices 1. The vertical movement height generally does not exceed 0.5 meters. The structure of the main mounting bracket 21 adopts a frame-type lightweight design while meeting the strength requirements. It generally uses hollow tubes, and its material is made of lightweight materials such as aluminum alloy or carbon fiber. After the design is completed, the strength and stiffness of the mounting bracket need to be checked.

[0024] A hydraulic shock absorber 25 is provided at the lower end of the main mounting bracket 21. The hydraulic shock absorber 25 can provide hydraulic buffering with the ground during the fall of the main mounting bracket 21, so as to avoid damage caused by hard contact between the main mounting bracket 21 and the thrust generating device 1 when they fall. The relevant parameters of the hydraulic shock absorber 25 are selected and verified according to the weight of the main mounting bracket 21 and the thrust generating device 1.

[0025] It was confirmed that the deformation and stress of the mounting bracket under the rated operating conditions of the thrust generator 1 were within the allowable range. The mounting guide rod 24 adopts a T-shaped structure and is fixed by the reinforcing support frame 22 to prevent deformation during the movement of the main mounting bracket 21 and the thrust generator 1. The lower end of the reinforcing support frame 22 is equipped with multiple evenly spaced movable casters 26. The specifications of the casters are selected according to the test site conditions and the total weight of the device to ensure smooth transportation of the device within the test site. During the test, the device is secured to the ground by the T-shaped mounting guide rod 24 on the reinforcing support frame 22 to ensure test safety.

[0026] The height H between the bottom surface of the thrust generator 1 and the ground is 1min H needs to be confirmed through methods such as flow field simulation. 1min It does not affect the free flow of the intake and exhaust of the thrust generating device 1, or the effect does not affect the key performance indicators of the thrust generating device 1.

[0027] Where H1 is based on It is determined that when the effects of the ground effect are completely eliminated, The above assumption is generally described in engineering terms as the relative thrust deviation caused by H1 being less than a certain small threshold. Right now It is obtained through mathematical derivation. ,in: The height above the ground is Yes, it's a vertical thrust. This refers to the thrust that is unaffected by height in free flow (i.e., the thrust when height H1→∞). H1 is the vertical height of the ducted fan outlet plane from the ground; D is the outlet diameter of the ducted fan; k is the ground effect coefficient, which depends on the geometry of the duct (lip shape, diffusion angle, etc.). For a typical ducted fan, the value of k is usually between 0.3 and 0.8. n is the attenuation rate constant, which is usually between 1.0 and 2.0; The thrust attenuation threshold caused by ground effects is generally taken as [value missing] in engineering. =1%.

[0028] The above analysis shows that for most single-rotor ducted fans, the minimum ground clearance H in engineering applications is... 1min 2D is recommended. 3D (i.e., 2 to 3 times the outlet diameter of the ducted fan). If the fan size is large and high control precision is required, a conservative value of >3.5D can be used.

[0029] The center distance between two adjacent thrust generators 1 located in the same row is L. min The layout of the thrust generator 1 should be as consistent as possible with its intended use scenario; if it cannot be consistent with the intended use scenario due to site or other reasons, then the minimum axial distance L between every two thrust generators 1 must be ensured. min It does not affect the uniformity of the air intake between thrust generating devices 1; generally, the inlet flow field non-uniformity is no greater than 1%. L min Designed as follows: L is based on the formula and It is determined that when the calculated TR value is greater than or equal to 1, it indicates that there is no thrust loss in a single thrust generator, meaning the spacing L is reasonably designed. The value is obtained when the spacing approaches the critical value. .

[0030] In the formula, L is the center distance of the thrust generator, and D is the diameter of the thrust generator.

[0031] In the formula This describes the attenuation of adverse interference. A (0 < A < 1) represents the maximum thrust loss ratio when the spacing is infinitely small (s ≥ 0). For example, A = 0.3 means that when the two fans are close together, the thrust loss is 30% (TR = 0.7); B (B > 0) is a constant controlling the attenuation rate of adverse interference; the larger B is, the faster the adverse interference disappears as the spacing increases; when s is very large, As the value approaches 0, this contribution approaches 1. It describes the contribution of the beneficial interference (ejection effect), which is a "hump" in the form of a Gaussian function; C > 0 indicates the maximum thrust gain caused by the ejection effect, and generally C > A; >0 indicates the optimal spacing ratio (position of the peak value of the hump) for generating maximum thrust gain; D>0 is a constant controlling the width of the hump. The larger D is, the narrower the hump, meaning that significant gain can only be achieved within a very narrow spacing range. In practical engineering, the critical value within the square root that yields a real number is often chosen based on the principle of mutual derivation, or L is directly chosen using empirical formulas. min ≥1.5D 2D is used to ensure safety.

[0032] like Figure 4 As shown, the movable engine mounting and adjusting device 4 includes a mounting bracket 41, a generator controller 42, an engine controller 43, a battery storage device 44, mounting screws 45, and movable casters 46.

[0033] Mounting bracket 41 is made of lightweight alloy material or ordinary carbon steel. Its design must consider the impact of the high-temperature, high-pressure gases emitted during the operation of the gas turbine engine and generator 3 on the device and the environment. The mounting surface of mounting bracket 41 features evenly distributed threaded holes to meet the installation requirements of different engines and to accommodate engine accessories. Mounting bracket 41 has multiple mounting surfaces to accommodate the installation of accessories such as generator controller 42, engine controller 43, and battery storage device 44. The gas turbine engine and generator 3 are mounted on mounting bracket 41, and are connected to the thrust generator 1 and can directly supply power to it.

[0034] The battery storage device 44 is mounted on the mounting bracket 41 and connected to the gas turbine engine and generator 3. The battery storage device 44 can store the electrical energy generated by the gas turbine engine and generator 3, and the battery storage device 44 is connected to the thrust generator 1 and can supply power to the thrust generator 1.

[0035] The distance between the outlet axis of the gas turbine engine and generator 3 and the ground is H. 2min H 2min The engine's intake and exhaust must flow freely, and small particles from the test site must not be sucked into the engine. Generally, the ground clearance should be no less than 1.2 meters. A dust removal device can also be added to the engine inlet. 2mi The design must comprehensively consider core engine parameters (such as airflow and thrust) and environmental factors (such as crosswinds), and be designed according to the following formula: ; In the formula: D is the engine inlet diameter (m), which is the reference dimension; This refers to the engine inlet air mass flow rate (kg / s), representing the engine's suction strength (which can be found in the engine performance manual or roughly estimated using the rated thrust, e.g., ...). (≈Thrust / 50) ρ is the air density (kg / m3), which is usually taken as the standard sea level air density value of 1.225 kg / m3; Crosswind speed (m / s) perpendicular to the engine axis is the main environmental factor that induces ground vortices and flow field distortion. k is the basic safety factor (dimensionless), with an empirical range of 1.5 to 2.0. Basic flow field distortion and foreign object (FOD) risk under seamless conditions are considered. α is the crosswind influence coefficient (dimensionless), with an empirical range of 0.1 to 0.3. It is used to adjust the intensity of the interaction between the crosswind and the engine.

[0036] Part One It is a static safety benchmark, even in the absence of wind ( Even when the airflow is 0, a minimum safe distance must be maintained to prevent airflow subsidence and potential ground vortices caused by the engine's own air intake; Part Two It is a dynamic increment, quantifying the impact of crosswinds. The larger the engine flow rate, the greater the safety distance required to counteract the resulting flow field distortion. The larger the flow field capture area, the stronger the interaction with the crosswind, and the greater the required aztreonnan distance.

[0037] The movable engine mounting and adjusting device 4 is equipped with mounting screws 45 and movable casters 46. The mounting screws 45 enable the movable engine mounting and adjusting device 4 to be installed and fixed during the test, and the movable casters 46 enable the movable engine mounting and adjusting device 4 to be moved within the test site during the test.

[0038] like Figure 5 As shown, the movable fuel tank 5 is connected to the gas turbine engine and generator 3 and can supply fuel to the gas turbine engine and generator 3. The movable fuel tank 5 consists of a handle 501, a lifting lug 502, a flip-top cleaning device 503, an oil inlet with oil filter 504, a sampling port / low-level fuel inlet 505, a drain port 506, casters 507, an observation hole 508, a high-level fuel inlet / spare port 509, and a level gauge 510.

[0039] The design pressure and volume of the movable fuel tank 5 are determined based on the engine's fuel supply pressure requirements and single-run time requirements. Generally, an atmospheric pressure fuel tank is used, and its volume must meet the fuel requirements for the longest single run time in the engine test procedure. The movable fuel tank 5 is generally made of materials such as stainless steel and is equipped with a grounding cable; if pressure fuel supply is used, the strength of the fuel tank needs to be checked.

[0040] The movable fuel tank 5 is equipped with multiple casters 507 to facilitate movement within the test site; multiple lifting lugs 502 are installed on the top for lifting during transport; and handrails 501 are provided for easy handling by test personnel within the site. The movable fuel tank 5 is equipped with a flip-top cleaning device 503, which can be flipped over for easy operation when cleaning is required. A rubber gasket is installed between the flip-top and the tank body to prevent fuel leakage or foreign matter from entering the tank. The movable fuel tank 5 is equipped with a fuel filler port 504 with a fuel filter. When filling, the filler port is opened, and the fuel enters the tank after being filtered by the fuel filter to ensure that the fuel cleanliness meets the test requirements. The movable fuel tank 5 is equipped with a sampling port / low-level fuel supply port 505, which can realize fuel sampling and low-level fuel supply; the bottom is equipped with a drain port 506, which is convenient for draining fuel when cleaning or replacing fuel; the top is equipped with an observation hole 508 and a high-level fuel supply port / spare port 509; and the side is equipped with a level gauge 510, which is convenient for monitoring fuel consumption during the test.

[0041] The volume of the movable fuel tank 5 is determined based on the rated fuel consumption rate and maximum single operating time of the selected gas turbine engine and generator 3. It is designed as an atmospheric pressure stainless steel tank and equipped with a grounding cable. The movable fuel tank 5 is connected to the fuel supply pipeline of the gas turbine engine and generator 3 via a sampling port / low-level fuel inlet 505 to supply fuel to the gas turbine engine and generator 3. The high-level fuel inlet / standby port 509 serves as a backup fuel supply interface or is used for switching between different fuel supply methods. A level gauge 510 is installed on the side of the tank for real-time monitoring of the fuel level by test personnel. The flip-top cleaning device 503 has a rubber gasket seal between the flip-top and the tank body to prevent fuel leakage or foreign objects from entering the tank. The movable fuel tank 5 is moved within the site via casters 507, lifted and transported via lifting lugs 502, and easily handled manually via handrails 501. The oil filler port 504 with oil filter ensures that each injected fuel is filtered, ensuring that the fuel cleanliness meets the test requirements; the drain port 506 is located at the bottom of the fuel tank, making it easy to drain fuel when cleaning or replacing fuel; the observation hole 508 is located at the top, for visual inspection of the internal condition of the fuel tank during daily inspections.

[0042] The above description is merely a specific embodiment of the present invention and should not be construed as limiting the scope of the invention. Therefore, any substitution of equivalent components or equivalent changes and modifications made within the scope of protection of this patent should still fall within the scope of this patent. Furthermore, the technical features, technical features and technical solutions, and technical solutions in this invention can be freely combined and used.

Claims

1. A mobile, distributed, low-to-medium power hybrid electric propulsion system ground test bench, characterized in that, include: The reinforced support frame (22) is fixedly connected to the ground. The reinforced support frame (22) is provided with a vertically arranged guide rail (24) and a height adjustment block (23) that can be detachably sleeved on the guide rail (24). The main mounting bracket (21) is equipped with multiple evenly spaced thrust generating devices (1); the main mounting bracket (21) is slidably connected to the reinforcing support frame (22).

2. The mobile distributed small-to-medium power hybrid electric propulsion system ground test apparatus according to claim 1, characterized in that, Multiple height adjustment blocks (23) are arranged sequentially along the axial direction of the guide rail (24).

3. The mobile distributed small-to-medium power hybrid electric propulsion system ground test apparatus according to claim 1, characterized in that, A hydraulic shock absorber (25) is provided at the lower end of the main mounting bracket (21). The hydraulic shock absorber (25) can provide hydraulic buffering with the ground during the fall of the main mounting bracket (21).

4. The mobile distributed small-to-medium power hybrid electric propulsion system ground test apparatus according to claim 1, characterized in that, The lower end of the reinforced support frame (22) is provided with multiple evenly spaced movable casters (26).

5. The mobile distributed small-to-medium power hybrid electric propulsion system ground test apparatus according to claim 1, characterized in that, The height between the bottom surface of the thrust generating device (1) and the ground is H1min, where, D is the outlet diameter of the ducted fan, k is the ground effect coefficient, and n is the attenuation rate constant. The thrust attenuation threshold caused by ground effects.

6. The mobile distributed small-to-medium power hybrid propulsion system ground test apparatus according to claim 1, characterized in that, The thrust generating devices (1) are arranged in two rows, symmetrically with respect to the centerline of the main mounting bracket (21). The center distance between two adjacent thrust generating devices (1) in the same row is Lmin, where, L is the center distance of the thrust generator, D is the diameter of the thrust generator, B is a constant controlling the attenuation rate of adverse interference, and C is the maximum thrust gain amplitude due to the ejection effect. The optimal pitch ratio for generating maximum thrust gain is A, which represents the maximum thrust loss ratio when the pitch is infinitely small.

7. The mobile distributed small-to-medium power hybrid electric propulsion system ground test apparatus according to claim 1, characterized in that, The mobile distributed small-to-medium power hybrid electric propulsion system ground test bench also includes a mobile engine mounting and adjustment device (4), which includes: Mounting frame (41) is equipped with a gas turbine engine and generator (3), which are connected to the thrust generating device (1) and can directly supply power to the thrust generating device (1); A battery storage device (44) is mounted on a mounting bracket (41) and connected to a gas turbine engine and a generator (3). The battery storage device (44) can store electrical energy from the gas turbine engine and the generator (3), and the battery storage device (44) is connected to a thrust generator (1) and can supply power to the thrust generator (1).

8. The mobile distributed small-to-medium power hybrid electric propulsion system ground test apparatus according to claim 7, characterized in that, The distance between the outlet axis of the gas turbine engine and generator (3) and the ground is H. 2min ,in, In the formula, D is the engine inlet diameter. The air mass flow rate at the engine inlet is ρ, where ρ is the air density. The crosswind speed perpendicular to the engine axis, k is the basic safety factor, and α is the crosswind influence factor.

9. The mobile distributed small-to-medium power hybrid electric propulsion system ground test apparatus according to claim 7, characterized in that, The mobile distributed small-to-medium power hybrid electric propulsion system ground test device also includes a mobile fuel tank (5), which is connected to the gas turbine engine and generator (3) and can supply fuel to the gas turbine engine and generator (3).

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