A measuring device and a measuring method for ice shape of rotating blade of icing wind tunnel

Abstract

The application discloses a kind of for icing wind tunnel rotating blade ice shape measuring device and measuring method, it is related to aero-engine icing test technical field.The measuring device includes base, horizontal rotating mechanism, vertical linear motion mechanism, horizontal linear motion mechanism, hot knife rotating mechanism, hot knife module and control system.Horizontal rotating mechanism is located on base and has first rotating output end;Vertical linear motion mechanism is located on first rotating output end and has vertical output end;Horizontal linear motion mechanism is located on vertical output end and has horizontal output end;Hot knife rotating mechanism is connected to horizontal output end and has second rotating output end;Hot knife module is connected to second rotating output end and includes heating blade;Control system is electrically connected with each motion mechanism respectively.The device is combined by four motion mechanisms in level, so that heating blade can be flexibly adjusted position and blade direction in three-dimensional space, realize the accurate measurement of blade surface ice shape.

Description

Technical Field

[0001] This application relates to the field of aircraft engine icing testing, and in particular to a measuring device and method for measuring the ice shape of rotating blades in an icing wind tunnel. Background Technology

[0002] When aero-engines pass through clouds containing supercooled water droplets, their intake fan blades are prone to icing. Icing alters the aerodynamic shape of the blades, leading to decreased engine thrust, reduced surge margin, and even damage to downstream components from detached ice, seriously threatening flight safety. Therefore, in aero-engine icing airworthiness verification and related experimental research, it is usually necessary to conduct rotating blade icing simulation tests using facilities such as icing wind tunnels. One of the core tasks of these tests is to accurately measure the ice shape adhering to the blade surface after icing has occurred.

[0003] The commonly used methods for measuring ice shape mainly include the following: Firstly, the hot-blade cutting method. This method typically involves the test personnel opening the hatch after the wind tunnel has stopped and using a heated blade to cut into the ice layer. A template is then used with ice-shaped paper to trace the ice-shaped cross-section. However, this method relies entirely on manual operation. Due to the confined space inside the wind tunnel and the complex geometry of the fan blades (such as forward sweep or twist), it is difficult for the operator to ensure that each cut is made at an angle perpendicular to the ice surface, resulting in uneven cut surfaces, poor measurement repeatability, and large errors.

[0004] Secondly, the three-dimensional laser scanning method. Although this method has high measurement accuracy, the laser often penetrates or produces severe diffuse reflection when dealing with transparent ice or surface frost, resulting in a large amount of missing point cloud data. In addition, the equipment is expensive and difficult to use in real time in the low temperature and high humidity environment of wind tunnel operation.

[0005] Thirdly, the mechanical probe or coordinate measuring machine method. Traditional coordinate measuring machines are bulky and cannot enter the icy wind tunnel test section to measure the icy blades, which limits their application in wind tunnel testing.

[0006] It is evident that the existing technology lacks an ice shape measurement device that can operate in the low-temperature and high-humidity environment of an icing wind tunnel and achieve high precision, high repeatability, and angle control for complex curved blades. Summary of the Invention

[0007] This application discloses a measuring device and method for measuring the ice shape of rotating blades in an icing wind tunnel, in order to solve the technical problems in related technologies, such as uneven ice shape cut surface and distorted measurement data caused by the difficulty of manually cutting into the ice layer at the optimal angle on the complex curved surface of the blade, as well as the technical problems of existing measuring equipment being too bulky to operate flexibly in the small space of the wind tunnel or model and making it difficult to achieve in-situ measurement.

[0008] To solve the above problems, this application adopts the following technical solution: In a first aspect, embodiments of this application provide a measuring device for measuring the ice shape of rotating blades in an icing wind tunnel, comprising: Base; A horizontal rotation mechanism is disposed on the base, and the horizontal rotation mechanism has a first rotation output end capable of rotating about a vertical axis; A vertical linear motion mechanism is disposed on the first rotary output end, and the vertical linear motion mechanism has a vertical output end that can reciprocate along the vertical direction; A horizontal linear motion mechanism is disposed on the vertical output end, and the horizontal linear motion mechanism has a horizontal output end that can reciprocate in the horizontal direction; A hot knife rotating mechanism is connected to the horizontal output end, and the hot knife rotating mechanism has a second rotating output end that can rotate about a vertical axis; A hot knife module is connected to the second rotary output end, and the hot knife module includes a heated blade; The control system is electrically connected to the horizontal rotation mechanism, the vertical linear motion mechanism, and the hot knife rotation mechanism, respectively. Secondly, embodiments of this application provide a method for measuring the ice shape of rotating blades in an icing wind tunnel, employing the aforementioned measuring device for measuring the ice shape of rotating blades in an icing wind tunnel, and including the following steps: Horizontal orientation step: The control system controls the horizontal rotation mechanism to rotate around the vertical axis, so that the heating blade points to the target measurement position of the rotating blade; Blade adjustment steps: The control system controls the hot knife rotation mechanism to rotate around the vertical axis, and adjusts the heating blade so that the cutting edge plane of the heating blade coincides with or is parallel to the target ice-shaped cross-section plane; wherein, the target ice-shaped cross-section plane is the plane where the ice-shaped cross-section to be measured is located at the target measurement position; Positioning steps: The control system controls the vertical linear motion mechanism to move and drives the horizontal linear motion mechanism to move the heating blade to the cutting start position; the cutting start position is located on the outside of the ice layer in front of the target measurement position, and a gap is reserved between the heating blade and the ice surface; Heating step: The heating blade is heated to a preset temperature by the control system; Cutting steps: After the heated blade reaches the preset temperature, control the horizontal linear motion mechanism and / or the vertical linear motion mechanism to feed along the preset feed direction that intersects with the target ice-shaped cross-section plane, and cut into the ice layer on the surface of the rotating blade from the cutting start position; Measurement steps: Obtain the profile data of the ice cross-section formed after the ice layer is cut.

[0009] The technical solutions adopted in the embodiments of this application can achieve the following beneficial effects: (1) The measuring device for ice shape of rotating blades in icing wind tunnels provided in this application is mainly applicable to the air intake rotating blades of aero engines, and is also applicable to the ice shape measurement of complex curved rotating components with large curvature and large torsion angle characteristics such as propellers and rotor blades (collectively referred to as "rotating blades" in this application). Through a hierarchical combination of a horizontal rotation mechanism, a vertical linear motion mechanism, a horizontal linear motion mechanism, and a hot blade rotation mechanism, a combination of two linear motion directions and two rotational motion directions around the vertical axis is achieved. This allows the heated blade to flexibly adjust its position in three-dimensional space and the orientation of its cutting edge in the horizontal plane. It can reach any measurement position on the blade surface and match the surface profile of the blade leading edge, chord direction, and other different orientations at different azimuth angles. When measuring ice shapes on complex curved surfaces with large curvature and large torsion angles, such as rotating blades, there is no need for repeated disassembly and adjustment. After one positioning, there is no need to readjust the overall position of the device. Measurements can be switched between different measurement positions on the same blade. When switching, it is only necessary to turn the horizontal rotation mechanism in the horizontal plane and reposition the heated blade to the new measurement position through the vertical and horizontal linear motion mechanisms. There is no need to move the base or reinstall the device, avoiding angular deviations and cross-sectional tilts caused by manual operation, thereby greatly improving the measurement accuracy and consistency of the ice shape cross-sectional profile.

[0010] (2) The measuring device for measuring the ice shape of rotating blades in an icing wind tunnel provided in this application has a high degree of integration and a small overall size due to the stacked layout of various motion mechanisms. After the icing test is completed, the device can be placed inside the wind tunnel test section. The ice shape measurement can be completed directly while the blade is in its original installation position on the model inside the wind tunnel. There is no need to remove the blade from the model or repeatedly adjust the blade position, which avoids the positional error caused by repeated disassembly and reassembly of the blade, simplifies the test process, and improves the measurement efficiency and measurement consistency. Attached Figure Description

[0011] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art 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.

[0012] Figure 1 This is a structural schematic diagram of an embodiment of this application; Figure 2 This is a side view of an embodiment of the present application; Figure 3 yes Figure 2 A magnified view of part A in the middle; Figure 4 This is a schematic diagram of the structure of the second sliding plate in the embodiments of this application; Figure 5 This is a schematic diagram of the slider arrangement in an embodiment of this application; Figure 6 This is a schematic diagram of the installation of the first skateboard in an embodiment of this application; Figure 7 This is an exploded view of the hot knife module installation in an embodiment of this application.

[0013] In the diagram: 10, base; 20, horizontal rotation mechanism; 30, mounting base; 40, mounting plate; 50, first slide plate; 60, vertical drive motor; 70, slide bar; 80, scale; 90, horizontal guide seat; 100, slider; 1001, slide groove; 110, second slide plate; 1101, guide rail; 120, rotary drive component; 130, output connection plate; 1301, mounting slot; 140, heating blade; 150, tool holder; 160, clamping plate; 170, lead screw transmission assembly. Detailed Implementation

[0014] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be described in detail below. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments in this application, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0015] The terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects and are not used to describe a specific order or sequence. It should be understood that such use of terms can be interchanged where appropriate so that embodiments of this application can be implemented in orders other than those illustrated or described herein, and the objects distinguished by "first," "second," etc., are generally of the same class and the number of objects is not limited; for example, a first object can be one or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0016] Among related technologies, the manual hot knife cutting method relies on operators holding a blade to cut the icy blades inside the wind tunnel. Due to the confined space inside the engine and the complex curved surface features of the rotating blades with large curvature and large twist angle, it is difficult for operators to ensure that the cutting angle is always perpendicular to the ice surface and cuts along the blade normal, resulting in uneven ice-shaped cut surfaces and significant problems with distorted measurement data. In addition, equipment such as 3D laser scanners and traditional coordinate measuring machines are bulky, and the engine model has a complex structure and confined space, which can easily block the laser, making it difficult to achieve in-situ measurement of the blades and limiting their application in icing tests.

[0017] To address this, this application proposes a measuring device and method for measuring the ice shape of rotating blades in an icing wind tunnel. The inventive concept is as follows: a hierarchical combination of a horizontal rotating mechanism 20, a vertical linear motion mechanism, a horizontal linear motion mechanism, and a hot blade rotating mechanism is adopted to integrate the rotational motion of the horizontal plane, the linear motion in the vertical and horizontal directions, and the rotational motion of the heated blade 140 around the vertical axis into one unit. Among them, the horizontal rotating mechanism 20, the vertical linear motion mechanism, and the horizontal linear motion mechanism jointly solve the problem of "spatial accessibility" for the heated blade 140 to reach any measurement position on the blade surface. The hot blade rotating mechanism solves the problem of "attitude matching" for adjusting the angle between the cutting edge direction of the heated blade 140 and the chord direction of the blade by rotating around the vertical axis. The control system coordinates the control of each motion mechanism according to the geometric characteristics of different measurement positions on the blade surface, so that the heated blade 140 can cut into the ice layer at a preset angle, thereby simultaneously achieving precise positioning in three-dimensional space and precise adjustment of the cutting edge direction. This overcomes the defects of uncontrollable angle of manual operation, poor measurement accuracy, and the inability of existing equipment to operate flexibly in situ in the wind tunnel.

[0018] Example 1:

[0019] This application provides a measuring device for measuring the ice shape of rotating blades in an icing wind tunnel, which is described below in conjunction with the attached diagram. Figures 1 to 7 This embodiment will be described in detail.

[0020] The rotating blades in this application refer to the air intake rotating blades of aero-engines, as well as complex curved rotating components with large curvature and large torsion angles, such as propeller and rotor blades. These components share the common characteristic that their blade surfaces exhibit a large curvature and twisted shape, and during ice shape measurement, the contour line of their measurement section shows significant changes in direction and angle at different chordal positions.

[0021] like Figures 1 to 3As shown, the measuring device mainly includes a base 10, a horizontal rotation mechanism 20, a vertical linear motion mechanism, a horizontal linear motion mechanism, a hot knife rotation mechanism, a hot knife module, and a control system. The horizontal rotation mechanism 20 is mounted on the base 10 and has a first rotational output end capable of rotating around a vertical axis, used to drive all components above it to rotate as a whole in the horizontal plane. The vertical linear motion mechanism is mounted on the first rotational output end of the horizontal rotation mechanism 20 and has a vertical output end capable of reciprocating in the vertical direction, used to drive the horizontal linear motion mechanism, the hot knife rotation mechanism, and the hot knife module to rise and fall to the target height. The horizontal linear motion mechanism is mounted on the vertical output end of the vertical linear motion mechanism and has a horizontal output end capable of reciprocating in the horizontal direction, used to drive the hot knife rotation mechanism and the hot knife module to move horizontally forward and backward to the target position. The hot knife rotation mechanism is connected to the horizontal output end of the horizontal linear motion mechanism and has a second rotational output end capable of rotating around a vertical axis, used to independently adjust the horizontal azimuth angle of the hot knife module. The hot knife module is connected to the second rotary output end of the hot knife rotating mechanism. The hot knife module includes a heated blade 140 for cutting ice in a heated state.

[0022] The control system is electrically connected to the horizontal rotation mechanism 20, the vertical linear motion mechanism, and the hot knife rotation mechanism, respectively, to coordinate and control the actions of each motion mechanism. The horizontal linear motion mechanism can be configured for automatic drive or manual operation mode according to actual needs. In automatic drive mode, the horizontal linear motion mechanism further includes a drive component electrically connected to the control system, whose action is controlled by the control system. In manual operation mode, the horizontal linear motion mechanism is driven manually by the operator, without needing an electrical connection to the control system. Both modes share the same mechanical guiding structure (the horizontal guide seat 90 slides against the second slide plate 110), differing only in the drive source, and can be flexibly selected according to measurement requirements and usage scenarios.

[0023] Through the hierarchical combination of the above four motion mechanisms, the horizontal rotation mechanism 20 realizes the overall orientation adjustment of the device in the horizontal plane, the vertical linear motion mechanism and the horizontal linear motion mechanism jointly realize the two-dimensional positioning of the heating blade 140 in the vertical and horizontal directions, and the hot blade rotation mechanism realizes the independent adjustment of the cutting edge direction of the heating blade 140 in the horizontal plane. The coordinated operation of the four motion directions enables the heating blade 140 to reach any measurement position on the blade surface and to match the chord direction at different positions on the blade surface at different azimuth angles, thereby achieving in-situ accurate measurement inside the wind tunnel without disassembling the blade. It can be understood that the control system is electrically connected to the horizontal rotation mechanism 20, the vertical linear motion mechanism and the hot blade rotation mechanism respectively, and is used to control the actions of the above three mechanisms. The horizontal linear motion mechanism can be configured as an automatic drive mode or a manual operation mode according to actual needs. The two modes share the same mechanical guide structure, only the drive source is different. In the automatic drive mode, the control system controls its action through the drive component, and in the manual operation mode, the operator pushes and pulls it manually.

[0024] In some embodiments, the vertical linear motion mechanism includes a mounting base 30, a mounting plate 40, a first sliding plate 50, and a vertical drive assembly. The mounting base 30 is fixedly mounted on the first rotary output end of the horizontal rotation mechanism 20. The mounting plate 40 is fixedly mounted on the mounting base 30 and extends vertically. The first sliding plate 50 is slidably engaged with the mounting plate 40 and can reciprocate vertically, forming the vertical output end of the vertical linear motion mechanism. The vertical drive assembly is located at the top of the mounting plate 40, its drive end is connected to the first sliding plate 50, and it is electrically connected to the control system. It is understood that by mounting the entire vertical linear motion mechanism onto the first rotary output end of the horizontal rotation mechanism 20 via the mounting base 30, when the horizontal rotation mechanism 20 rotates around its vertical axis, the mounting base 30, its mounting plate 40, the first sliding plate 50, and the vertical drive assembly rotate accordingly, thereby causing the entire upper structure to adjust its orientation in the horizontal plane. The first slide plate 50 and the mounting plate 40 are guided vertically through a sliding fit. The vertical drive component drives the first slide plate 50 to reciprocate vertically from the top. The structure is compact and the motion transmission is direct. It can accurately transmit the output of the vertical drive component to the first slide plate 50, so as to achieve precise control of the vertical position of the heating blade 140.

[0025] In some embodiments, the vertical drive assembly includes a vertical drive motor 60 and a lead screw drive assembly 170. The vertical drive motor 60 is fixedly mounted on the top of the mounting plate 40, and the lead screw drive assembly 170 is connected between the output shaft of the vertical drive motor 60 and the first slide plate 50, for converting the rotational motion of the vertical drive motor 60 into the reciprocating linear motion of the first slide plate 50 in the vertical direction. The vertical drive motor 60 is a low-temperature resistant servo motor and equipped with an absolute encoder, which can achieve precise control of the vertical position of the first slide plate 50.

[0026] In some embodiments, the mounting plate 40 is provided with a vertically extending slide bar 70, and the first sliding plate 50 is provided with a sliding groove 1001 that slidably engages with the slide bar 70; or, the mounting plate 40 is provided with a vertically extending sliding groove 1001, and the first sliding plate 50 is provided with a slide bar 70 that slidably engages with the sliding groove 1001. It is understood that the sliding engagement structure of the slide bar 70 and the sliding groove 1001 provides precise guidance for the vertical movement of the first sliding plate 50 relative to the mounting plate 40, effectively constraining the degree of freedom of the first sliding plate 50 in non-movement directions, and ensuring the straightness and stability of the vertical movement. The engagement method of the slide bar 70 and the sliding groove 1001 can be flexibly selected according to specific processing conditions and load-bearing requirements, such as using different forms like T-shaped cross-sections, trapezoidal cross-sections, or rectangular cross-sections, expanding the applicable scenarios of the device, and also facilitating the selection of appropriate guide structure forms based on blade size and weight. In other embodiments, to improve the stability of vertical guidance, there can be two mounting plates 40. The two mounting plates 40 are fixedly mounted on the mounting base 30 in parallel and at intervals. The first sliding plate 50 is disposed between the two mounting plates 40. The above-mentioned guide structure is provided between each mounting plate 40 and the first sliding plate 50, thereby providing guide constraints on both sides of the first sliding plate 50 at the same time, further improving the rigidity of vertical movement and resistance to eccentric loads.

[0027] In some embodiments, a scale 80 is provided vertically to indicate the vertical position of the first slide plate 50. This scale 80 can be mounted on the mounting base 30 and extend vertically, or it can be mounted on the side of the mounting plate 40 or other vertically fixed components. The zero point of the scale 80 corresponds to the initial position of the vertical linear motion mechanism. When the operator manually operates the horizontal linear motion mechanism, the current vertical height of the heating blade 140 can be directly read through the scale 80, facilitating rapid height positioning between different measurement points. Simultaneously, the scale 80 can also serve as an independent verification benchmark for the encoder feedback signal of the vertical drive component. When the encoder signal drifts in low-temperature environments, it can assist the operator in judging positioning deviations, further improving the ease of use in manual operation scenarios and the reliability of position verification in automatic control mode.

[0028] In some embodiments, the horizontal linear motion mechanism includes a horizontal guide seat 90 and a second slide plate 110. The horizontal guide seat 90 is fixedly mounted on the vertical output end (i.e., the first slide plate 50), and a slider 100 is fixedly mounted on the horizontal guide seat 90. The slider 100 has a horizontal groove 1001. The second slide plate 110 has a guide rail 1101, which extends horizontally and is embedded in and slidably engages with the groove 1001, thereby allowing the second slide plate 110 to reciprocate horizontally relative to the horizontal guide seat 90. One end of the second slide plate 110 forms a horizontal output end, used to connect to the hot knife rotating mechanism and drive it to move horizontally.

[0029] As a further embodiment, the slider 100 is fixedly mounted on the horizontal guide seat 90 via an auxiliary fixing plate. Specifically, the auxiliary fixing plate is fixedly mounted on the horizontal guide seat 90, and the slider 100 is fixedly mounted on the auxiliary fixing plate.

[0030] As a further embodiment, the sliders 100 are arranged in two rows, staggered, with each slider 100 having a horizontal groove 1001. This staggered arrangement avoids interference between the two rows of sliders during movement and ensures more uniform force distribution on the horizontal guide seat 90 along its sliding direction, thus improving the structural rigidity and smoothness of the horizontal linear motion mechanism. The second slide plate 110 has two guide rails 1101, respectively located on both sides of the second slide plate 110 and facing each other. The two guide rails 1101 correspond one-to-one with the grooves 1001 on the two rows of sliders 100. By sliding the two rows of sliders 100 in pairs with the two guide rails 1101, the second slide plate 110 is constrained on both sides during horizontal sliding, resulting in symmetrical force and smooth movement. This is beneficial to improving the guiding accuracy and load-bearing capacity of the horizontal linear motion mechanism, effectively constraining the offset of the second slide plate 110 in the horizontal plane perpendicular to the sliding direction and the deflection around the vertical axis, and ensuring the straightness of the horizontal movement trajectory of the heating blade 140.

[0031] In some embodiments, the horizontal linear motion mechanism further includes a horizontal drive assembly. The drive end of the horizontal drive assembly is connected to the second slide plate 110 via a transmission connection, and the horizontal drive assembly is electrically connected to the control system. It is understood that the horizontal drive assembly provides a driving force for the horizontal reciprocating movement of the second slide plate 110. Its installation position can be flexibly set according to the actual structural layout. For example, it can be fixed on the vertical output end, located on the outer side of the end of the second slide plate 110 away from the horizontal output end, or it can be fixed on the extension bracket of the base 10 or other fixed structures, as long as its drive end can form a reliable transmission connection with the second slide plate 110. When the control system issues a control command to the horizontal drive assembly, the horizontal drive assembly drives the second slide plate 110 to reciprocate horizontally relative to the horizontal guide seat 90 via its drive end, realizing the automatic feeding or retraction of the heating blade 140 in the horizontal direction. This configuration allows the horizontal linear motion mechanism to move precisely to the target position according to a preset path without manual intervention in automatic control mode.

[0032] In some embodiments, the horizontal drive assembly includes a horizontal drive motor and a transmission assembly. The horizontal drive motor is located on the outer side of the second slide plate 110 away from the horizontal output end, and the transmission assembly is connected between the output shaft of the horizontal drive motor and the second slide plate 110. The transmission assembly can be any one of a ball screw pair, a synchronous belt drive pair, or a rack and pinion drive pair, used to convert the rotational motion of the horizontal drive motor into the reciprocating linear motion of the second slide plate 110 in the horizontal direction. The horizontal drive motor is a high-low temperature servo motor equipped with an absolute encoder, which can realize precise closed-loop control of the horizontal position of the second slide plate 110.

[0033] As another parallel implementation, the horizontal linear motion mechanism can also be operated manually. In this mode, the horizontal linear motion mechanism does not have a horizontal drive assembly (i.e., no drive motor and corresponding electrical transmission assembly), but a manual operating component (such as a handle) can be installed on the second slide plate 110. The operator directly drives the second slide plate 110 to reciprocate horizontally relative to the horizontal guide seat 90 by pushing or pulling the manual operating component, thereby manually feeding or retracting the heating blade 140 in the horizontal direction. The manual operation mode uses the same mechanical guiding structure as the automatic drive mode described above (i.e., the sliding engagement between the horizontal guide seat 90 and the second slide plate 110), the only difference being the source of the driving force. In the automatic mode, the driving force is provided by the horizontal drive motor, while in the manual mode, the operator applies a pushing or pulling force. The two modes can be flexibly selected according to actual needs.

[0034] In some embodiments, the hot knife rotation mechanism includes a rotary drive 120 and an output connecting plate 130. The rotary drive 120 is fixedly mounted on the horizontal output end (i.e., one end of the second slide plate 110), and the output connecting plate 130 is connected to the second rotary output end of the rotary drive 120. The hot knife module is fixedly connected to the output connecting plate 130. The rotary drive 120 is mounted on the output end of the horizontal linear motion mechanism (i.e., one end of the second slide plate 110). When the horizontal linear motion mechanism drives the second slide plate 110 to move horizontally, the rotary drive 120, the output connecting plate 130, and the hot knife module move together. The rotary drive 120 drives the output connecting plate 130 to rotate around the vertical axis through the second rotary output end, thereby driving the hot knife module to rotate around the vertical axis. This arrangement allows the cutting edge direction of the heated blade 140 in the horizontal plane to be precisely adjusted independently of other movements, thereby adjusting the cutting edge azimuth angle according to the chord direction at different positions on the blade surface to achieve the optimal cutting angle. Since the rotation axis of the hot knife module and the rotation axis of the horizontal rotation mechanism 20 are both vertical, they form a series relationship in kinematics. The horizontal rotation mechanism 20 is responsible for the large-scale orientation of the vertical linear motion mechanism, the horizontal linear motion mechanism, the hot knife rotation mechanism, and the hot knife module as a whole relative to the blade. The hot knife rotation mechanism is responsible for the precise fine adjustment of the cutting edge direction of the heated blade 140. The two functions complement each other.

[0035] In some embodiments, the rotary drive 120 is a rotary motor (such as a stepper motor or a servo motor) and is fixedly mounted on the horizontal output end. After the rotary motor is powered on, it drives the second rotary output end to rotate around the vertical axis, thereby causing the output connecting plate 130 and the hot knife module fixed thereon to rotate together, so as to achieve precise adjustment of the cutting edge direction of the heated blade 140 in the horizontal plane.

[0036] In some embodiments, the heated blade module also includes a handle 150, with a heated blade 140 fixedly mounted at one end of the handle 150. The handle 150 is made of an insulating material (such as PEEK or ceramic), which effectively prevents heat from the heated blade 140 from being transferred to the rotary drive 120 and the horizontal linear motion mechanism, thus avoiding thermal damage or deformation of the moving parts due to high temperatures. The heated blade 140 is made of brass, which has excellent thermal conductivity and can quickly heat up to a temperature sufficient to melt and cut ice after being energized. Brass also has appropriate hardness and wear resistance, ensuring that the cutting edge remains sharp after multiple cuts. The cutting edge thickness of the heated blade 140 is controlled to be less than or equal to 1.5 mm, which helps reduce cutting resistance, resulting in a smoother and flatter cutting surface, facilitating the accurate acquisition of subsequent ice shape contour data.

[0037] In some embodiments, the output connection plate 130 is provided with a mounting groove 1301 adapted to the tool holder 150. The tool holder 150 is embedded in the mounting groove 1301 and fixedly mounted on the output connection plate 130 by a clamping plate 160. Specifically, the shape of the mounting groove 1301 is adapted to the shape of the tool holder 150. After the tool holder 150 is embedded in the mounting groove 1301, the mounting groove 1301 provides circumferential positioning and load-bearing support. The clamping plate 160 spans over the mounting groove 1301 and covers at least a portion of the tool holder 150. The clamping plate 160 is fixedly connected to the output connection plate 130 by fasteners (such as screws), pressing and fixing the tool holder 150 in the mounting groove 1301. With the cooperation of the mounting slot 1301 and the clamping plate 160, the tool holder 150 is reliably fixed on the output connection plate 130, which can transmit the rotary motion output by the rotary drive component 120, withstand the cutting reaction force generated during the cutting process, and facilitate the installation, removal and replacement of the tool holder 150.

[0038] In some embodiments, the hot knife module also includes a temperature sensor for detecting the temperature of the heated blade 140. The temperature sensor is positioned close to the heated blade 140 and is electrically connected to the control system. By detecting the temperature of the heated blade 140 in real time and feeding the temperature signal back to the control system, the control system can perform closed-loop adjustment of the heating power of the heated blade 140 according to a preset temperature threshold, ensuring that the heated blade 140 is always within the optimal operating temperature range during the cutting process. If the temperature is too low, the ice layer cannot be effectively melted and cut; if the temperature is too high, the ice layer may melt excessively, destroying the original outline of the ice shape. The temperature sensor effectively avoids the above problems, ensuring the consistency and reliability of the cutting quality.

[0039] In some implementations, the horizontal rotation mechanism 20 can be a direct-drive rotary table or a worm gear rotary table. Direct-drive rotary tables feature low backlash, high precision, and high rigidity, making them suitable for applications requiring high angular positioning accuracy. Worm gear rotary tables have self-locking characteristics, making them suitable for applications bearing large loads and requiring the vehicle to maintain its current position after power failure. Both options can be selected based on actual usage requirements, and both can achieve high-precision rotary motion around the vertical axis. Furthermore, low-temperature resistant lubricating layers or anti-freeze heating bands can be installed on the moving parts of the horizontal rotation mechanism 20, the vertical linear motion mechanism, the horizontal linear motion mechanism, and the hot knife rotation mechanism. Since the working temperature inside the icing wind tunnel test section is typically as low as -30°C or even lower, ordinary grease will solidify and thicken at low temperatures, leading to increased frictional resistance or even jamming of moving parts. By coating moving parts with a low-temperature resistant lubricating layer or filling them with low-temperature resistant grease, and by installing anti-freeze heating bands to actively heat critical moving parts, it is possible to effectively prevent moving parts from jamming due to lubrication failure or surface icing in low-temperature and high-humidity environments, ensuring the flexibility and reliability of each moving mechanism in low-temperature environments.

[0040] In some embodiments, the control system employs a programmable logic controller (PLC), which is electrically connected to the drive motors of the horizontal rotating mechanism 20, the vertical linear motion mechanism, and the hot knife rotating mechanism, respectively. For the horizontal linear motion mechanism, in automatic drive mode, its drive component is electrically connected to the PLC, and the PLC controls its movement according to a preset program or operating instructions. In manual operation mode, the horizontal linear motion mechanism does not have a drive component; the operator drives it horizontally using a manual control element. In this case, no electrical connection is required between the PLC and the horizontal linear motion mechanism. The PLC features high reliability, strong anti-interference capability, simple programming, and stable operation in low-temperature environments, making it suitable for complex working conditions in icing wind tunnel test sections.

[0041] Example 2:

[0042] This application provides a method for measuring the ice shape of rotating blades in an icing wind tunnel, using the measuring device for measuring the ice shape of rotating blades in an icing wind tunnel as described in Example 1, and includes the following steps: Step S10, Installation and Fixing Step: Fix the base 10 to the designated position within the icing wind tunnel test section.

[0043] Specifically, the base 10 can be fixed to the ground or mounting platform inside the icing wind tunnel test section using bolts or quick-release clamps. The installation position should ensure that the rotating blades are within the operating range of the horizontal and vertical linear motion mechanisms. Due to the compact size of the device, it can be installed entirely inside the wind tunnel test section after the icing test. Measurements can be taken directly with the blades in their original installation positions within the wind tunnel, eliminating the need to remove the blades from the model and avoiding positional resetting errors caused by repeated disassembly and reassembly.

[0044] Step S20, Horizontal Orientation Step: Control the horizontal rotation mechanism 20 to rotate around the vertical axis through the control system, so that the heating blade 140 points to the target measurement position of the rotating blade.

[0045] Specifically, since the rotating blades are arranged circumferentially, the circumferential positions of different blades are different, and the azimuth angles of different measurement positions of the same blade are also different in the horizontal plane. By controlling the horizontal rotation mechanism 20 to rotate around the vertical axis, the vertical linear motion mechanism, horizontal linear motion mechanism, hot knife rotation mechanism, and hot knife module mounted on the first rotation output end rotate as a whole, so that the above mechanisms and the hot knife module as a whole rotate in the horizontal plane to the location of the target blade. This step solves the problem of the horizontal orientation of the heating blade 140 in the horizontal plane, enabling the heating blade 140 to approach the target blade from any circumferential orientation, achieving effective coverage of a large range of different blade positions.

[0046] Step S30, Blade Adjustment Step: Control the hot knife rotation mechanism to rotate around the vertical axis through the control system, and adjust the heating blade 140 so that the cutting edge plane of the heating blade 140 coincides with or is parallel to the target ice-shaped cross-section plane; wherein, the target ice-shaped cross-section plane is the plane where the ice-shaped cross-section to be measured is located at the target measurement position.

[0047] Specifically, since the surface profile of the rotating blade is different at different blade height positions (the blade itself is twisted), and the leading edge region and trailing edge region have different curvature directions, after horizontal orientation and before positioning, the cutting edge direction of the heated blade 140 is adjusted by the hot blade rotation mechanism according to the actual geometric characteristics of the rotating blade surface at the target measurement position, so that the cutting edge plane of the heated blade 140 coincides with or is parallel to the target ice-shaped cross-section plane.

[0048] For example, when it is necessary to obtain an ice-shaped cross section across the extension direction of the rotating blade surface, the cutting edge direction of the heated blade 140 can be made perpendicular to the extension direction of the rotating blade surface at that location. This angle setting is beneficial for accurately reflecting the thickness distribution of the ice layer in the airflow direction.

[0049] For example, when measuring the ice shape near the leading edge of a rotating blade, the cutting edge direction of the heating blade 140 can be adjusted appropriately to match the arcuate direction of the leading edge. By adjusting the cutting edge direction, the cutting edge plane of the heating blade 140 coincides with or is parallel to the target ice shape cross-sectional plane, ensuring that the height of the cut ice shape cross-section is consistent with the target ice shape cross-sectional plane, thus avoiding measurement data distortion caused by angular deviation.

[0050] Step S40, Positioning Step: The vertical linear motion mechanism and the horizontal linear motion mechanism are controlled by the control system to move the heating blade 140 to the cutting start position. The cutting start position is located on the outside of the ice layer in front of the target measurement position, and a gap is reserved between the heating blade 140 and the surface of the ice layer.

[0051] Specifically, the control system controls the vertical drive assembly to drive the first slide plate 50 to slide vertically to the target height position, and controls the horizontal linear motion mechanism to drive the second slide plate 110 to move horizontally to the target horizontal position. Through the coordinated linear motion in both the vertical and horizontal directions, the heating blade 140 is moved to the cutting start position. In this step, the heating blade 140 is positioned at the cutting start position in front of the ice surface, with a gap (2mm to 5mm) between this position and the ice surface. This gap effectively reduces the thermal impact of the heating blade 140 on the ice surface during preheating, while ensuring that the heating blade 140 can quickly feed to the ice surface during the cutting step. The heating blade 140 has not yet contacted the ice surface, thus providing operating space for subsequent heating steps and preventing the heat from the heating blade 140 from being directly conducted to the ice surface during preheating, which could damage the ice shape. During the positioning process, the control system reads the position feedback signals from the encoders of each motion mechanism in real time to ensure that the positioning accuracy meets the measurement requirements.

[0052] Step S50, Heating Step: With the heating blade 140 maintaining a pre-reserved gap with the ice layer, the heating blade 140 is heated to a preset temperature by the control system.

[0053] Specifically, the control system powers the heating blade 140 to a preset temperature via a heating circuit. A temperature sensor monitors the temperature of the heating blade 140 in real time and feeds the temperature signal back to the control system. The control system then performs closed-loop regulation of the heating power based on the temperature signal, ensuring that the temperature of the heating blade 140 remains stable within the preset temperature range. During the heating process, because there is a gap between the heating blade 140 and the ice surface, heat is not directly conducted to the ice surface, avoiding damage to the ice shape caused by preheating. At the same time, the preset temperature is configured to precisely meet the minimum effective temperature required for cutting the ice layer, preventing the heating blade 140 from overheating. This ensures cutting capability while minimizing the impact of heat on the ice layer during the cutting process.

[0054] Step S60, Cutting Step: After the heated blade 140 reaches the preset temperature, control the horizontal linear motion mechanism and / or the vertical linear motion mechanism to feed along the preset feed direction that intersects with the target ice-shaped cross-section plane, so that the heated blade 140 cuts into the ice layer on the surface of the rotating blade from the starting position to be cut.

[0055] Specifically, after the heated blade 140 reaches a preset temperature, the control system controls the horizontal drive component to drive the second slide plate 110 to move horizontally, and / or controls the vertical drive component to drive the first slide plate 50 to move vertically, so that the heated blade 140, starting from the starting position to be cut, feeds into the ice layer along a preset direction intersecting the target ice-shaped cross-section plane. Since the heated blade 140 has been preheated to the preset temperature before cutting, it possesses sufficient cutting capability the instant it contacts the ice layer, enabling it to cleanly and efficiently cut into the ice layer in the shortest possible time, obtaining a smooth ice-shaped cut surface. Simultaneously, it minimizes the time window for heat transfer to the ice layer, avoiding thermal damage to the ice-shaped contour. Furthermore, since the overall orientation and precise adjustment of the cutting edge direction of the heated blade module have been completed before cutting through horizontal orientation, vertical orientation, and blade adjustment steps, the heated blade 140 can precisely cut into the ice layer at a preset angle during the cutting process.

[0056] It should be noted that during the cutting process, a cooling device simultaneously sprays rapid refrigerant onto the cutting location to maintain the low temperature of the ice layer around the cutting area, preventing heat conduction from the heated blade 140 from causing localized melting of the ice layer in adjacent areas. By simultaneously spraying rapid refrigerant through the cooling device, the blowing direction of the rapid refrigerant during cutting is coordinated with the feed direction of the heated blade 140, ensuring that the ice accumulated in the adjacent cutting area remains at a low temperature and does not melt during the cutting process, thereby maximizing the fidelity of the ice shape acquisition. Simultaneous spraying of rapid refrigerant during cutting is a conventional technique in this field and will not be elaborated upon here.

[0057] Step S70, Retraction Step: Control the horizontal linear motion mechanism and / or the vertical linear motion mechanism to drive the heated blade 140 to retract to the initial position in the opposite direction of the preset feed direction.

[0058] Timely retraction of the blade after cutting can minimize the risk of excessive melting of the ice layer due to prolonged contact with the heated blade 140 within the ice. It also provides unobstructed space for subsequent acquisition of the ice cross-sectional contour data. During the retraction process, the control system automatically generates a retraction path based on the feed path, ensuring a smooth retraction process without damaging the already cut ice cross-section.

[0059] Step S80, Measurement Step: Obtain the ice-shaped cross-sectional profile data formed after the ice layer is cut.

[0060] Specifically, after the heated blade 140 completes the cutting and retracts, a contact measuring tool (such as a probe) or a non-contact measuring tool (such as a structured light scanner) can be used to collect data on the exposed ice-shaped cross-section after cutting, obtaining parameters such as the thickness, contour, and tangential distribution of the ice layer. Because the cutting surface is flat and the angle is precise, the obtained ice-shaped cross-section data can truly reflect the actual shape of the ice layer on the blade surface.

[0061] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element.

[0062] Furthermore, it should be noted that the scope of the methods and apparatus in the embodiments of this application is not limited to performing functions in the order shown or discussed, but may also include performing functions substantially simultaneously or in the reverse order, depending on the functions involved. For example, the described methods may be performed in a different order than described, and various steps may be added, omitted, or combined. In addition, features described with reference to certain examples may be combined in other examples.

[0063] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application.

Claims

1. A measuring device for measuring the ice shape of rotating blades in an icing wind tunnel, characterized in that, include: Base; A horizontal rotation mechanism is disposed on the base, and the horizontal rotation mechanism has a first rotation output end capable of rotating about a vertical axis; A vertical linear motion mechanism is disposed on the first rotary output end, and the vertical linear motion mechanism has a vertical output end that can reciprocate along the vertical direction; A horizontal linear motion mechanism is disposed on the vertical output end, and the horizontal linear motion mechanism has a horizontal output end that can reciprocate in the horizontal direction; A hot knife rotating mechanism is connected to the horizontal output end, and the hot knife rotating mechanism has a second rotating output end that can rotate about a vertical axis; A hot knife module is connected to the second rotary output end, and the hot knife module includes a heated blade; The control system is electrically connected to the horizontal rotation mechanism, the vertical linear motion mechanism, and the hot knife rotation mechanism, respectively.

2. The measuring device for measuring ice shape of rotating blades in an icing wind tunnel according to claim 1, characterized in that, The vertical linear motion mechanism includes: The mounting base is fixedly mounted on the first rotary output end; A mounting plate is fixedly mounted on the mounting base, and the mounting plate extends in the vertical direction; The first sliding plate is slidably engaged with the mounting plate, and the first sliding plate can slide back and forth in the vertical direction, forming the vertical output end; A vertical drive assembly is disposed at the top of the mounting plate. The drive end of the vertical drive assembly is connected to the first slide plate, and the vertical drive assembly is electrically connected to the control system.

3. The measuring device for measuring ice shape of rotating blades in an icing wind tunnel according to claim 2, characterized in that, The mounting plate is provided with a slide bar extending in a vertical direction, and the first sliding plate is provided with a groove that slides and engages with the slide bar; or, the mounting plate is provided with a groove extending in a vertical direction, and the first sliding plate is provided with a slide bar that slides and engages with the groove.

4. The measuring device for measuring ice shape of rotating blades in an icing wind tunnel according to claim 2, characterized in that, A scale is provided along the vertical direction to indicate the vertical position of the first slide plate.

5. The measuring device for measuring ice shape of rotating blades in an icing wind tunnel according to claim 1, characterized in that, The horizontal linear motion mechanism includes: A horizontal guide seat is fixedly mounted on the vertical output end; The second slide plate slides in a horizontal direction with the horizontal guide seat, and the horizontal output end is located at one end of the second slide plate.

6. The measuring device for measuring ice shape of rotating blades in an icing wind tunnel according to claim 5, characterized in that, The horizontal linear motion mechanism further includes a horizontal drive component, the drive end of which is connected to the second slide plate, and the drive component is electrically connected to the control system.

7. The measuring device for measuring ice shape of rotating blades in an icing wind tunnel according to claim 1, characterized in that, The hot knife rotation mechanism includes: A rotary drive component is fixedly mounted on the horizontal output end and electrically connected to the control system. An output connection plate is connected to the second rotary output end of the rotary drive component, and the hot knife module is fixedly connected to the output connection plate.

8. The measuring device for measuring ice shape of rotating blades in an icing wind tunnel according to any one of claims 1 to 7, characterized in that, The hot knife module also includes a handle, and the heating blade is fixedly disposed at one end of the handle; the handle is made of heat-insulating material, the heating blade is made of brass, and the cutting edge thickness of the heating blade is less than or equal to 1.5 mm; The hot knife module also includes a temperature sensor for detecting the temperature of the heating blade. The temperature sensor is arranged close to the heating blade and is electrically connected to the control system. The horizontal rotation mechanism adopts a direct-drive rotary table or a worm gear rotary table; The moving parts of the horizontal rotation mechanism, the vertical linear motion mechanism, the horizontal linear motion mechanism, and the hot knife rotation mechanism are coated with a low-temperature resistant lubricating layer and / or are provided with an antifreeze heating belt.

9. A method for measuring the ice shape of rotating blades in an icing wind tunnel, comprising the measuring device for measuring the ice shape of rotating blades in an icing wind tunnel as described in any one of claims 1-8, characterized in that, Includes the following steps: Horizontal orientation step: The control system controls the horizontal rotation mechanism to rotate around the vertical axis, so that the heating blade points to the target measurement position of the rotating blade; Blade adjustment steps: The control system controls the hot knife rotation mechanism to rotate around the vertical axis, and adjusts the heating blade so that the cutting edge plane of the heating blade coincides with or is parallel to the target ice-shaped cross-section plane; wherein, the target ice-shaped cross-section plane is the plane where the ice-shaped cross-section to be measured is located at the target measurement position; Positioning steps: The control system controls the vertical linear motion mechanism to move and drives the horizontal linear motion mechanism to move the heating blade to the cutting start position; the cutting start position is located on the outside of the ice layer in front of the target measurement position, and a gap is reserved between the heating blade and the ice surface; Heating step: The heating blade is heated to a preset temperature by the control system; Cutting steps: After the heated blade reaches the preset temperature, control the horizontal linear motion mechanism and / or the vertical linear motion mechanism to feed along the preset feed direction that intersects with the target ice-shaped cross-section plane, and cut into the ice layer on the surface of the rotating blade from the cutting start position; Measurement steps: Obtain the profile data of the ice cross-section formed after the ice layer is cut.

10. The method for measuring ice shape on rotating blades in an icing wind tunnel according to claim 9, characterized in that, It also includes a blade retraction step: controlling the horizontal linear motion mechanism and / or the vertical linear motion mechanism to drive the heated blade to retract in the opposite direction of the preset feed direction; the blade retraction step is performed after the cutting step and before the measurement step.

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