Aero-Engine Altitude Test Flight Monitoring System
Project name: Aero-Engine Altitude Test Flight Monitoring System
A national aero-engine research institute implemented DE-series real-time dynamic parameter analysis and monitoring systems for comprehensive data acquisition during altitude test flights, enabling critical performance validation under simulated operational conditions.
1. System Configuration
| Parameter | Measurement Technology | Specifications |
|---|---|---|
| Pulsating Pressure | High-frequency Kulite Sensors | 0-5MPa, 50kHz bandwidth |
| Blade Vibration | Tip-timing Optical Probes | 0.1μm resolution @ 1200°C |
| Dynamic Stress | High-Temperature Strain Gauges | ±5000με, 10kHz sampling |
| Static Structural Load | Fiber Bragg Grating Sensors | 2000Hz multiplexed measurement |
| Shaft Torque | Telemetric Strain Rings | ±1% accuracy at 30,000RPM |
2. Core Functions
Real-Time Monitoring:
Continuous tracking of 50+ critical parameters at 1ms intervals
Automatic alert triggering for:
Pressure pulsations exceeding ±15% nominal
Vibration amplitudes >8mm/s (ISO 10816-3 Class A limits)
Data Processing Workflow:
3. Key Test Objectives
Operational Envelope Verification
Validate performance at 15-20km altitude conditions
Characterize compressor stall margins
Structural Dynamics Analysis
Monitor blade flutter onset (0-5kHz range)
Detect casing thermal deformation
Control System Validation
Verify FADEC response to transient conditions
Record surge recovery characteristics
4. System Technical Highlights
Extreme Environment Operation
Functions reliably at -65°C~300°C ambient temperatures
Withstands 40g vibration during emergency maneuvers
Advanced Signal Processing
Real-time order tracking for shaft harmonics
Adaptive noise cancellation for combustion signals
Safety-Critical Architecture
Dual-redundant data paths (MIL-STD-1553B + Ethernet)
99.999% data integrity ensured by CRC-64 checksums
5. Engineering Outcomes
Performance Validation:
Identified 7% thrust loss at high-altitude relight conditions
Optimized fuel schedule improved relight success rate to 98%
Safety Enhancements:
Prevented 3 potential surge events through early detection
Reduced emergency shutdowns by 60% compared to previous tests
Maintenance Benefits:
Established vibration baselines for condition-based maintenance
Detected bearing wear 50 hours prior to predicted failure
