System Design A New Aero-engine Enclosed Test Cell

Aero-Engine enclosed test cell research has important theoretical significance and application value. Since the1920s, Aero-engine performance improves continuously, the functional requirements of the engine test cell have improved simultaneously, and the traditional test cell already cannot meet the test requirements for the production of aviation engines. According to the test and process performance requirements of XX66series aero-engine repair lines and taking the Southern Company XX66series aero-engine II test cell as the master of test cell, the Southern Company has self-designed the113test cell of the air force repair plant and implement the automatic acquisition and automatic control testing process of parameters, improved test accuracy and stability of test cell at the same time.Main Research and design work of this paper are as follows(1) The overall design ideas, test theory and compositions of engine test cell are described in detail. According to the general test cell design ideas, the main control room and overall layout is designed; The composition and architecture of test cell is determined after analyzing the pipeline connection layout between engine and test cell from the test principle; Based on II test cell and construction standard, the functions of each subsystem is determined. Lastly, the design scheme of various subsystems is established respectively.(2) The Needs analysis of data acquisition system is conducted about four aspects, as functional requirements, performance requirements, technical parameters and user needs. Based on the Needs analysis, a overall building planning of the data acquisition system, application-level model of the system and the individual task allocation scheme of each PC is programmed. Then, a data acquisition system is proposed, which is based on VXI bus test techniques and Lab Windows/CVI development tool. Lastly, with both hardware and software aspects of the design of the Aero engine test cell data acquisition system, the various functions of the hardware and software systems simulation Test block is determined. Then, the sources of noise are analyzed, as well as the affect way into the data acquisition system. Detailed analysis to specific interference of data acquisition system, and correctly and effectively use of Anti-interference technology, as shielding, grounding and filtering. Both hardware and software aspects of the system’s anti-jamming scheme is designed to ensure the safe and stable operation of the system, as well as accuracy and reliability.(3) In order to exhaust the engine exhaust smoothly of test cell exhaust system, the engine’s, and ensure the intake and exhaust do not interfere with each other interference, a systematic study of multi-directional lead shot exhaust of test cell is conducted. The exhaust ejector tube geometry is designed according to aerodynamic firstly, and the modeling and aerodynamic analysis carried out using Fluent software. Lastly, the ejector amounts are calculated in three states, which contributed to verifying the feasibility of the design. Meanwhile, the aerodynamic analysis with different angles can provide a theoretical basis for engine test cell exhaust ejector system of future new models.(4) The introduction of domestic and foreign engine calibration method classification is made. Then the engine parameters conversion formula is corrected according to the specific test situation. The calibration test is carried out using a standard prototype and the test station is determined according to the accuracy of the measured values. Lastly, the debug and improvement scheme is identified basing on the calibration station.The developed test cell of this paper has been successfully applied in the air force repair plant XX66Series aero-engine repair lines, the testing capabilities and technical indicators fulfill the needs of practical application, and ensure a considerable precision.