Aero-engine Test Run Integrated Monitoring Technology And Fault Diagnosis System Development

In the 1970’s, it was the first time to put forward aero-engine gas path electrostatic monitoring technology. It has been succeed in several projects. This paper discusses the availability of new electrostatic sensor, and analyzes the variable trend combined with the electrostatic signal characteristic parameters and the performance parameters based on turbofan engine test run. This paper also designs electrostatic monitoring and fault diagnosis system. The main contents are list below:(1) The electrostatic monitoring scheme applied to civil aviation turbofan engine experiment is proposed. A study of online monitor and signal processing is carried out. According to the experiment environment, a new electrostatic sensor is designed, and strength check proves it safe and reliable.(2) A simulation experiment platform is designed to simulate typical gas path faults of aero engine. The experiments compare the electrostatic signal characteristics of different materials and different particle speed, and analyze signal rules which can explain the phenomenon occurred in test run reasonably.(3) “Aero-Engine Gas Path Electrostatic Monitoring & Fault Diagnosis System” is developed based on Lab VIEW. The system contains electrostatic signal acquisition, real-time signal processing, data storage and threshold alarm. In addition, studies of electrostatic baseline and fault mode identification based on SVM are carried out. Two off-line signal analysis and diagnosis modules are developed, which can analyze and process off-line data.(4) An electrostatic monitoring experiment on civil aviation turbofan engine which is still in service is carried out. The experiment analyzes the variable trend combined with the electrostatic signal characteristic parameters and the performance parameters in total test run stage. Functional relationship between activity level and thrust in the steady thrust stage is proposed. Several engine faults about oil leaking and fuel-rich combustion are monitored by electrostatic sensor via on-line system and off-line module.