Engine Test Stands Research Articles

Метрологічне забезпечення та автоматизація випробувань регулятора малорозмірного газотурбінного авіадвигуна

The subject of this research was the possibility of creating a control and verification apparatus (CVA) for ensuring full-scale autonomous tests of the regulator of a small gas turbine aircraft engine developed at the enterprise. The purpose of this study was to develop CVA (a modern small-sized hardware and software complex that allows automating the performance tests, which is carried out as during the production technological cycle of the regulator, as well as in operation) based on information about the aircraft engine characteristics, including refinement of its mathematical model based on experimental data. The tasks faced by the developers were to determine the optimal set of functions of the equipment, which would provide sufficient data for a reliable assessment of the regulator's performance based on the test results while minimizing the time spent and the probability of errors, and the implementation of the function of automated performance of complete regulator measuring channels calibration, including the pressure measurement channel (together with the pressure sensor) and the fuel flow measurement channel (with the sensor of the angle of rotation of the dosing element of the fuel dispenser). The applied methods are follows: at the first stage of design it was the analysis of available data on the processes that need to be automated, after that the experimental method of research the first sample characteristics and its interaction with the aircraft engine was applied at the developer’s test base (JSC “Element”) and at engine test stands of JSC "Motor Sich", and then – a method of statistical data processing, including refinement of the mathematical model of the aircraft engine. The results. The developed CVA consists of a hardware part structurally designed in the form of a CVA block weighing 1.7 kg with built-in software and a software product installed on a personal computer. The mathematical model of the aircraft engine integrated into the built-in software allows you to perform a full-fledged check of the regulator's functioning, in particular, at the start of the engine, at the maintenance of the specified operating mode, while ensuring protection against exceeding the permissible values of the parameters. The scientific novelty of the obtained results is the development of the CVA with an integrated engine mathematical model and a set of functions that provide a full autonomous regulator operability check, which was verified in the process of testing on real engine. The practical significance of the obtained results lies in the fact that the production and operation of the newly developed aircraft engine regulator is equipped with a compact and easy-to-use means of full-fledged operational automated control of its performance.

Surge and Choke Capable Compressor Model

AbstractA compressor model is developed. It is capable of representing mass flow and pressure characteristic for three different regions: surge, normal operation as well as for when the compressor acts as a restriction, i.e. having a pressure ratio of less than unity. Different submodels are discussed and methods to parametrize the given model structure are given. Both the parametrization and validation are supported extensively by measured data. Dynamic data sets include measurements from engine and surge test stands. The compressor model is further validated against a database of stationary compressor maps. The proposed model is shown to have good agreement with measured data for all regions, without the need for extensive geometric information or data.

Metallurgical Investigation of Cracked Adaptor Welded to Cryogenic Dump Coolant Line of Engine Test Stand

In the upper stages of satellite launch vehicles, a cryogenic propulsion system is used because of its high specific impulse. Such stages were tested for qualification using ground hot test facility. During one of the hot tests, the stainless steel adaptor welded to the engine dump coolant line, and used for accommodating temperature sensors, broke away from the tube. The detailed metallurgical investigation was carried out, and the reason for cracking was attributed to improper welding. This article highlights the details of investigation carried out.

Pyrolysis/gasification of biomass for synthetic fuel production using a hybrid gas–water stabilized plasma torch

An experimental plasma-chemical reactor equipped with a novel hybrid gas–water stabilized torch is available at IPP Prague for the innovative and environmentally friendly plasma treatment of waste streams with a view to their sustainable energetic and chemical valorization and to a reduction of the emission of greenhouse gases. Gasification/pyrolysis of biomass was experimentally studied using crushed wood as a model substance. The experimental results demonstrate homogeneous heating of the reactor volume and proper mixing of plasma with treated material in spite of the low plasma mass flow rate and constricted plasma jet. The conditions within the reactor ensure complete destruction of the tested substance. The economical viability, environmental performance and safety of biofuels/hydrogen produced from syngas resulting from the plasma-thermochemical gasification of a very broad range of second generation biomass feedstock will be investigated. The performance of several types of plasma torches and of possible combinations of torches will be compared. The final biofuels will be tested in the existing Internal Combustion Engine (ICE) test stands.

Static and Dynamic Calibration of Pressure Transducers at Elevated Temperatures

The Air Force conducts tests requiring measurement of high dynamic pressures in high-temperature environments. Such tests require measurement of dynamic pressures created by jet engines, turbulent air-flow along hot areas of aircraft structures, and acoustic levels in Air Force test chambers such as acoustic chambers, wind tunnels, and engine test stands. Several commercial industries also have requirements for high-temperature dynamic measurements. To address these Air Force needs for dynamic pressure measurements at high temperatures, the Structures Division of the Flight Dynamics Directorate of the Wright Laboratory evaluated dynamic pressure transducers for use in extreme acoustic and thermal environments. Transducer manufacturers were surveyed and three off-the-shelf pressure transducers capable of measuring dynamic pressures at extreme environments were identified. The first model measures up to 194 dB(A) and operates up to 260°C (500°F). This model has an extended operating temperature up to 1649°C (3000 °F) when used with a water-cooled jacket. The second model is an air-cooled transducer advertised to operate up to 593°C (1100°F). The third model is a water-cooled transducer advertised to operate up to 2802°C (5075 °F). Two of the models have low sensitivity and thus require more output amplification. These two models are also larger and require larger mounting holes. The transducers were evaluated at various static pressures, acoustic levels, and temperatures. This paper describes the procedures used to calibrate these transducers up to a 172-dB sound pressure level (SPL) and a temperature of 732°C (1350°F). The results for these transducers are summarized for different static pressures, operating SPLs, and temperatures.

VLSI system design for automotive control

Presents a novel VLSI approach for combustion engine control. The approach is based on a real-time solution of a thermodynamical differential equation. The control system calculates an optimum ignition point by fast measurement and real-time processing of signals as temperature, pressure, and volume of the combustion chamber. The required computational power cannot be met with standard signal processors. The design of a mechatronic system that is based on an application-specific vector architecture is presented. Each design step from the analysis of the heat release algorithm, the optimization of the algorithm and the dataform, the mapping on architecture, the physical design of the testchip set and the single chip, the chip test, and the system integration, is presented. Finally, the application at an engine test-stand and results are shown. >

Thermal-oxidative stability of oils under dynamic conditions

This article describes an apparatus designated as PVL-2, which was developed at the S. Shaumyan Leningrad Experimental Petroleum Oil Plant in order to determine the thermal-oxidative stability of oils in thin, isolated films under dynamic conditions. Examines a typical plot of frictional torque, section by section, obtained in the PVL-2 apparatus for AU spindle oil at 200 C. Also investigated are the kinetics of varnish formation; the influence of heating rate on operation of DS-11 oil; and the effects of additives on thermal-oxidative stability of AU spindle oil. Suggests that further commercial manufacture and use of the PVL-2 apparatus will contribute to faster and much less expensive laboratory and screening tests (before engine test-stand evaluations) on various oils that have been synthesized.

ENGINE TEST BED FILTRATION at BRITISH LEYLAND

ONE of the most important requirements of the assembly and testing plant of the No. 2 Kings Norton Birmingham factory of British Leyland is a bulk supply of engine and automatic‐gearbox oil that is free from any type of contamination including air, gases and moisture. This must be immediately accessible on demand at each of ten engine test stands, three gearbox rigs, one pump rig, and one gearbox rectification bay.