RU2746378C1 - Test method for aircraft gas turbine engine - Google Patents

Abstract

FIELD: jet tech.

SUBSTANCE: invention relates to the field of jet technology, in particular to the field of diagnostics, repair, acceptance and delivery of gas turbine engines for aircraft and power plants operating on liquid and gaseous fuels. The proposed method for testing an aircraft gas turbine engine in bench conditions during presentation, acceptance, service life and special tests includes measuring the parameters of the engine operation at various modes within the range of engine flight modes, bringing the obtained parameters to standard atmospheric conditions, taking into account the maintenance of the specified laws of regulation and changes in the properties of the heat capacity of the working fluid and the geometry of the flow path during engine tests in atmospheric conditions that do not correspond to standard ones. According to the test results of prototypes of engines of this series, engine parameters are determined, both under standard atmospheric conditions, and not. A method for processing test results using two independent programs for engine debugging has been implemented. On the basis of the average statistical characteristics of the engine elements, the tuning performed while maintaining the given control laws, correction factors are determined to the measured basic engine parameters, according to which the measured parameters relate to the parameters obtained under standard atmospheric conditions. Real-time visualization of the correlation links of parameters with the function of selecting these links from the database is carried out.

EFFECT: use of the invention allows to increase the level of verification of the technical characteristics of products and to debug and assess their compliance with technical conditions, to organize the search for design flaws and their elimination, to eliminate the human factor, simultaneously with the tests to debug new programs and mathematical models of the engine, to reduce the test time by 1-2%.

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Description

The invention relates to the field of jet technology, in particular to the field of diagnostics, repair, acceptance and delivery of gas turbine engines for aircraft and power plants operating on liquid and gaseous fuels.

A known method for testing an aircraft gas turbine engine, adopted as a prototype, consists in the experimental determination of the quantitative and / or qualitative properties of the engine and / or its units and their compliance with the specified requirements, when operating as a result of regulatory influences, including the implementation of preparatory operations and operations on the engine on test bench, carrying out acceptance tests with debugging of parameters and adjustment of all its systems and checking for compliance with the technical conditions of the assembly quality and the main engine parameters to the specified values, selection of the engine from the batch that has passed acceptance tests, carrying out bench life tests on it, comparison of the registered values of the criteria engine with given values and the formation, based on the results of comparison, of a conclusion on the admission of engines to further operation with the initial assigned or changed resource, after which the acceptance and dispatch of the remainder flax engines of this batch in operation.

/ RU 2 365 891 C1 IPC G01M 15/14 Published on August 27, 2009 /

The disadvantage of this method is the limited number of recorded and estimated parameters for various types of engine tests, which in modern conditions, with increased requirements for the reliability of engines and the performance of its systems (fuel, oil, electrical circuits, control-recording and recording equipment, etc.) is insufficient. This is especially important after the return of the engine from operation or after its long-term storage, when complete information on the technical condition of units, modules, assemblies and parts becomes mandatory, the identification of the amount of repair and replacement of failed parts with the disassembly of the engine and special types of control and special types tests. The known method, due to the limited number of recorded and evaluated parameters for various types of tests, allows only partially assessing the technical condition of the engine, and, therefore, cannot guarantee reliable operation when returning the engine to operation during the assigned or newly installed resource.

The objective of the invention is to expand the functionality of testing the performance of units, assemblies and engine parts.

The expected technical result is an increase in the reliability of the assessment of the technical condition of a new or repair engine, an increase in the efficiency of the use of repair technology for a step-by-step increase in the engine resource to the value specified in the regulatory and technical documentation for a batch or for the entire series of engines, an increase in the reliability of operation when the engine is returned to operation in the flow of an assigned or newly installed resource.

The specified technical result is achieved by the fact that the proposed method for testing an aircraft gas turbine engine consists in performing preparatory operations on the bench, operations on the engine and experimental determination of the quantitative and / or qualitative properties of the engine and / or its units and their compliance with the specified requirements, while functioning as a result regulatory actions, including the performance of preparatory operations and operations on the engine - testing, data processing and the formation of a conclusion on the admission of engines to further operation with the initial assigned or changed resource, acceptance and sending the remaining engines of this batch into operation, at the following stages:

A) preparation of bench tests

- Selection of the type of tests and equipping the engine and / or its units and the test bench with measuring instruments in accordance with the specified in the list of measured parameters characterizing the properties of the object that meet the specified requirements for the selected type of tests;

- Dissection of the engine with sensors and its installation on a test bench;

- Organization of at least four automated workstations (AWS), interconnected and with the actuators of the test bench and the engine and sensors on the engine and equipped accordingly:

a) Workplace of a shift engineer (AWS) - information on the laws of regulation of the position of the guide vanes of high and low pressure compressors, depending on the speed of rotation of the high and low pressure rotors reduced to standard conditions;

c) Workplace of the settlement team (AWP) - information about the current operating mode of the engine, the selected type of tests and the type of logging;

c) Workstation "(AWP) Test" - built-in modules necessary for direct testing and testing the developed software modules and mathematical models in the process of testing;

d) Visualization workstation (AWS) - information about the values of the selected parameters from the database containing information about the previous tests of the engines of this series.

B) testing

- Creation by artificial means, using additional methods and means, of external influencing factors similar to the conditions arising during operation and the selected type of tests;

- Measurement of parameters when external influencing factors change in accordance with the selected regulation law, similar to the impact conditions during operation;

- Direct measurement of parameters, without the use of analytical dependencies, reflecting the physical structure of the engine under test.

- Systematization of data,

C) data processing

- Registration of the real flow of experimental data for the selected templates;

- Formation of a model based on the formulation of goals and description of the object, development of a simulator program, algorithmization, programming and debugging of the model;

- Creation of databases for objects that have similar structural and technological solutions, the test results of which apply to the entire group.

D) test management

- Analytical comparison of the values of the measured parameters and the required values contained in the block (database) of conditionality.

- Establishing the reasons for deviations in the parameters of the quantitative and (or) qualitative characteristics of the properties of the object and their non-compliance with the specified requirements;

- Development of ways to compensate for deviations, drawing up protocols (databases) of compliance.

The use and maintenance of characteristic operating modes that ensure the quantitative and / or qualitative properties of the engine and / or its components and their compliance with the specified requirements and draw up compliance database protocols to form a conclusion on the admission of engines to further operation.

The essence of bench tests of aircraft gas turbine engines is to register the current values of the engine condition criteria, compare them with the specified reference values, conduct bench bearer, acceptance, service life and special tests with debugging parameters and adjusting all its systems and checking for compliance with the technical conditions of assembly quality and basic engine parameters to the set values.

The choice of the type of tests and the equipment of the engine with measuring instruments is carried out, according to the list of measured parameters characterizing the properties of the object that meet the specified requirements for the selected type of test, preparation of the engine and its installation on the test bench, organization of automated workstations, creation of external influencing factors similar to the conditions arising during operation and the selected type of tests, measurement of parameters when external influencing factors change in accordance with the selected regulation law, similar to exposure conditions during operation, direct measurement of parameters, without using analytical dependencies reflecting the physical structure of the engine under test, data systematization, including the creation of databases for engines, having similar constructive and technological solutions, registration of experimental data, formation of a model based on the formulation of goals and description of the object, development of simulator programs, algorithmization, programming and debugging of the model, analysis of the values of measured parameters and the required values contained in the condition database, determination of the reasons for deviations in the parameters of quantitative and / or qualitative characteristics of the object's properties and their non-compliance with the specified requirements, development of ways to compensate for deviations, drawing up protocols compliance databases, as well as the use of characteristic operating modes that ensure the quantitative and qualitative properties of the engine and their compliance with the specified requirements.

A feature of the proposal is to equip the test bench with at least four automated workstations (AWS) connected to each other and to the actuators of the test bench and the engine and sensors on the engine.

An automated workstation (AWS) for a shift engineer, equipped to ensure the testing process, is additionally supplied with information on the laws of regulating the position of the guide vanes of high and low pressure compressors, depending on the speed of rotation of high and low pressure rotors reduced to standard conditions, depending on the selected type tests, the type of logging and the current operating mode of the engine.

The automated workstation (AWS) of the calculation team is equipped to ensure the process of adjusting engine parameters, registering data of physical and calculated parameters, as well as generating measurement test reports, additionally supplied with information about the current engine operation mode, the selected type of tests and the type of logging.

The automated workstation "AWP Test" is intended for testing the newly developed software modules and mathematical models in the process of testing, with the aim of further analyzing the correctness of their work, as well as duplicating the registration of data of physical and calculated parameters in case of failures or failures in the operation of other AWPs. All modules necessary for testing are built directly into the "Test Workstation".

An automated workstation (AWS) of visualization is equipped to ensure the process of visual control of the correlation of the physical and design parameters of the engine during the testing process, and is additionally supplied with information about the values of the selected parameters from the database containing information about the previously conducted tests of engines of this series.

All automated workstations of the test bench receive a real stream of experimental data through the measuring channels from the sensors, by transmitting information through the data collection systems to the server of the measuring and computing complex and its subsequent distribution. Additionally, the reception of data on the conditionality of measurements from the corresponding program unit, which transmits information about the reliability of the readings of the sensors, is organized.

The invention is illustrated by graphic materials.

FIG. 1 is a schematic block diagram of the implementation of the proposed method;

FIG. 2 - the dependence of the static pressure behind the HPC on the rotational speed;

FIG. 3 - dependence of the gas temperature behind the injection pump on the rotational speed.

The method for diagnosing and repairing gas turbine engines includes the following operations:

1 - determination of the list of measured and calculated parameters;

2 - preparation of the engine on a test bench;

3 - testing;

4 - selection of the type of tests;

5 - measurement of parameters;

6 - data collection;

7 - data processing;

8 - data logging;

9 - creating a database;

10 - determination of operating modes;

11 - control from the workstation of the shift engineer;

12 - control from the workstation of the settlement team;

13 - control from the visualization workstation;

14 - test workstation control;

15 - conditioning unit;

16 - types of protocols;

17 - laws of regulation.

Measurements of the engine operation parameters in various modes within the range of engine flight modes, bringing the obtained parameters to standard atmospheric conditions, taking into account the maintenance of the specified control laws and changes in the properties of the heat capacity of the working fluid and the geometry of the flow path during engine tests in atmospheric conditions, differ from the standard ones. Based on the test results of prototypes of engines of this series, the mathematical model of the engine is corrected, according to which the engine parameters are determined, both under standard atmospheric conditions and those differing from standard ones. To debug the corrective mathematical model of the engine, the method of processing test results using two independent programs was used. On the basis of the average statistical characteristics of the engine elements, the tuning performed while maintaining the given control laws, correction factors are determined to the measured basic engine parameters, according to which the measured parameters relate to the parameters obtained under standard atmospheric conditions. Real-time visualization of the correlation links of parameters with the function of selecting these links from the database. The developed test method is applicable for fine-tuning and automated debugging of experimental and serial engines to the specified standards, and also allows using a mathematical model of the engine to identify substandard measurements in real time. This test method increases the reliability of measurements and reduces labor intensity, saves energy when debugging engines.

The method allows not only to expand the functionality of checking the engine's performance, but also to reduce the engine debugging time and the number of starts by increasing the information content of processing, generating a library of registered data files obtained during all previous tests of this engine and other engines of this series, formed by the type of tests and the achieved consumer properties.

An example of the implementation of the method.

The engine was delivered to the test stand for life tests to check the technical characteristics of the product and assess their compliance with the technical conditions, to check the reliability of the product, its systems and assemblies within 1000 hours of the resource. The type of tests is selected - resource 4 (figure 1), which provides testing 3 (figure 1) with the necessary techniques, test programs, lists of measured parameters and software of the measuring and computing complex. A list of measured and calculated parameters 1 (Fig. 1) is determined, according to the program of life tests, according to this list, the engine is prepared on a test bench 2 (Fig. 1). Bench tests are carried out under atmospheric conditions, with air and fuel heating at the inlet to the product, according to a program with strict adherence to the operating time schedule at maximum and forced modes, total operating time and the number of variable modes and nozzle rotation cycles. Measurement of parameters 5 (figure 1) is carried out with various types of measuring equipment, for which an individual data acquisition system (DAC) has been developed. The server receives and processes data 7 (Fig. 1) from all DSS combined into a common Ethernet subnet (packet data transmission technology) and generates a single data packet for the entire measurement system, and sends it to all automated workstations (AWS). The data collection tool 6 (Fig. 1) from the system sensors polls the measuring channels with a frequency of up to 100 Hz with simultaneous registration of information 8 (Fig. 1) directly on the controller or a personal computer PC and entry into the database 9 (Fig. 1).

AWPs 11, 12, 13, 14 (Fig. 1) are designed for receiving, processing, displaying and recording data, tolerance control of parameters, generating measurement protocols and reports. "Workstation of the settlement team" 12 (Fig. 1) is designed to ensure the process of adjusting engine parameters, registering data of physical and calculated parameters, as well as generating measurement test reports, is additionally supplied with information about the current operating mode of the engine, the selected type of tests and the type of logging. The main algorithms of the programs (definitions of conditions, high-speed mathematical model (BMM), etc.) are built into the PC “Workstation of the settlement team”. Additionally, the reception of data on the conditionality of measurements 15 (Fig. 1) is organized from the corresponding program unit, which transmits information about the reliability of the readings of the sensors to all AWPs of the test bench. Thus, in FIG. 2 graphically shows how the substandard measurement of the static pressure downstream of the high pressure compressor (Pk static) is determined and FIG. 3 identification of the defect and its elimination by measuring the temperature of gases behind the turbine (tt) for the "maximum training" mode. BMM determines the throttle characteristics of the dependences of the reduced pressure (Pk statics pr) 22 (Fig. 2) and the reduced gas temperature behind the turbine (tt pr) 31 (Fig. 3) on the reduced revolutions of the low pressure compressor (N1пр) and the tolerance depending on the number of cycles: 23 (figure 2), 32 (figure 3) from 1 to 50 cycles; 24 (Fig. 2), 33 (Fig. 3) from 51 to 100 cycles; 25 (Fig. 2), 34 (Fig. 3) from 101 to 150 cycles. Conditioning unit 15 (Fig. 1) on cycle 60 determined the substandard measurement of Pc statics 26 (Fig. 2) and on 76 and 87 cycles an additional check of measurement tt 35.36 (Fig. 3) and transmitted a message to the workstation of the shift engineer 11 (Fig. .1), with a proposal to continue the start-up with replacing the measurement of Pk statics with its mathematical expectation and measuring tt for measuring the temperature of gases behind the turbine of the engine measurement system (tt crd), and after starting, check the measurement of Pk statics for conditioning and identify the reason for the measurement of tt for tolerance zones.

After starting, a leak was found in the connection for measuring Pk static and after tightening the lock nut, the leak was eliminated.

The unit for determining the operating mode 10 (Fig. 1) determined that the measurement of tt at the 76th cycle was made at a cold outlet on an unheated product 36 (Fig. 3), therefore, the unit for determining the operating mode removed the non-standard measurement, and on the 87th cycle, the non-standard measurement remained 35 (Fig. 3) and a recommendation was issued to inspect the flow path of the turbine. After inspection, a burnout of the nozzle blade was found, the detected defect was recorded in the main protocol and the nozzle block was replaced.

On the workstation of the shift engineer 11 (Fig. 1), the block of regulation laws 17 (Fig. 1) transfers all the characteristics and dependences of the parameters of a certain type of engine to a specific type of test. After completing the tests, the technician selects and prints the required types of protocols 16 (Fig. 1). Throttle characteristics (22 Fig. 2 and 31 Fig. 3) are displayed on the visualization workstation 13 (figure 1) to control the correlation of the physical and design parameters of the engine during testing, as well as the visualization workstation is additionally supplied with information about the values of the selected parameters from the database, containing information about previous tests of engines of this series.

Figures 2 and 3 show the selected parameters from the database depending on the number of cycles performed: from 1 to 50 cycles 19 (figure 2), 28 (figure 3); 51 to 100 cycles 20 (Fig. 2), 29 (Fig. 3); from 101 to 150 cycles 21 (Fig. 2), 30 (Fig. 3), as well as the data obtained on the characteristic before the endurance tests 18 (Fig. 2) and 27 (Fig. 3). AWP Test 14 (Fig. 1) is designed to test the newly developed software modules and mathematical models in the process of testing for the purpose of subsequent analysis of the correctness of their work, as well as duplication of registration of data of physical and design parameters in case of failures or failures in the operation of other AWPs. All modules necessary for testing are built directly into the Test Workstation.

Lifetime tests are carried out according to the full program with strict adherence to the operating time of various modes and the number of performed variable modes and cycles. To exclude the human factor and optimize the testing at the automated workplace of the settlement team 12 (Fig. 1), a unit for determining and calculating the operating time of modes and the number of variable modes and cycles is installed.

All information is systematized in the Table - performance of operating time, injectors, checks and re-adjustments of PRS for life tests.

The table shows the protocol of operating time and the number of modes at the end of life tests. In the “total” column, the required number of tests and events determined by the program of endurance tests, in the “performed” and “left” columns, the number of tests and events performed and their missing remainder, in the “cycles left” and “routinely for cycles” columns, the number is not stages performed for life tests and the number of events in one stage. The block for determining and calculating the operating time of modes and the number of variable modes and cycles automatically determines the number of completed and necessary modifications of events. In the column of the table "must be performed additionally", in order to exclude the human factor during testing, the deviation from the program of all tests carried out is displayed, taking into account that the remaining stages of the test will be carried out without deviation from the test program. So the total operating time of the product must be additionally refined on the two remaining cycles 12 minutes 34 seconds, line 1 of the table, while the additional operating time in afterburner modes should be 1 minute 32 seconds, line 5 of the table. The program determined that the number of non-afterburning thrusters of the "training" mode line 12 of the table is one more, therefore, it should not be performed on one of the remaining cycles, and the number of swings of the rotary jet nozzle (PRS) must be additionally completed 7 swaps in line 16 of the table.

Routine work and inspections of the flow path based on test results.

It is determined that it is necessary to modify at the forced training mode for 12.5 minutes, 10 injectors at variable modes.

The application of the invention allows - to increase the level of verification of the technical characteristics of products and to debug and assess their compliance with the technical conditions, to organize the search for design flaws and their elimination, to eliminate the human factor, simultaneously with the tests to debug new programs and mathematical models of the engine, to reduce the test time by 1 2%.

Claims (6)

1. A method for testing an aircraft gas turbine engine, including the performance of preparatory operations on the stand, operations on the engine and the experimental determination of the quantitative and / or qualitative properties of the engine and / or its units and their compliance with the specified requirements, during its operation as a result of regulatory influences, testing, data processing and the formation of a conclusion on the admission of engines to further operation with the initial assigned or changed resource, acceptance and dispatch of the remaining engines of this batch for operation, characterized in that they select the type of tests and equip the engine and / or its components and test bench with sensors and measuring instruments , according to the list of measured parameters characterizing the properties of the object corresponding to the selected type of tests, at least four automated workstations are organized, connected to each other and with the actuators of the test bench and the engine, create an artificially, with the help of additional methods and means, external influencing factors, similar to the conditions arising during engine operation with the selected type of tests, measure the parameters when external influencing factors change in accordance with the selected regulation law, similar to the impact conditions during engine operation and record a real flow of experimental data according to the selected templates, according to experimental data, based on the formulation of goals and description of the object, a model is formed that provides for the development of a simulator program, algorithmization, programming and debugging of the model, after which databases are created for objects that have similar design and technological solutions , the test results of which apply to the entire group, while making an analytical comparison of the values of the measured parameters and the required values contained in the condition database, establish the reasons for the deviation parameters of the quantitative and / or qualitative characteristics of the properties of the object and their non-compliance with the specified requirements, develop ways to compensate for deviations by maintaining characteristic operating modes that ensure the quantitative and / or qualitative properties of the engine and / or its components and their compliance with the specified requirements and draw up protocols of compliance databases to form a conclusion on the admission of engines to further operation. 2. The method according to claim 1, characterized in that the following are used as automated workstations: a) shift engineer workplace - equipped with information on the laws of regulation of the position of the guide vanes of high and low pressure compressors depending on the speed of rotation of the high and low pressure rotors reduced to standard conditions; c) workstation of the settlement team - equipped with information about the current operating mode of the engine, the selected type of tests in the form of logging; c) "Test" workstation - equipped with built-in modules necessary for direct testing and testing the developed software modules and mathematical models in the process of testing; d) visualization workstation - equipped with information on the values of the selected parameters from a database containing information on previous tests of engines of this series.

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