Digital twin-driven optimization of gas exchange system of 2-stroke heavy fuel aircraft engine

Abstract

Multiple parts in gas exchange system of 2-stroke heavy fuel aircraft engine with poppet valves lead to complicated manufacturing and inefficient assembly. Besides, real experimental optimization wastes lots of time and cost due to the increased valve parameters. To address the above issues, the paper proposes a digital twin (DT)-driven optimization method with several DT modules for the system to virtually simulate and optimize the parameters, performance and manufacturing with data interaction and recorded. The DT modules receive real-time feedback data from manufacturing measurements and performance tests to conduct the correction throughout the optimization process. The results demonstrate that the virtual engine model with feedback and correction is quite precise and credible compared with test results, and iterative calculation for optimal parameters is performed efficiently. With the guidance of virtual manufacturing, real manufacturing and assembly are arranged more reasonably and efficiency has been promoted. Real-world test found both power and gas exchange performance improved about 4% under various engine speeds and loads, which verified the effectiveness of DT-driven optimization. The study achieves the integration between virtual and real worlds of the system performance and manufacturing, which facilitates the development of aircraft engine smart manufacturing.