Vibration and Strain Testing for Aero-Engine Components
This case outlines a vibration and strain testing project undertaken by a technology group to analyze the dynamic behavior of aero-engines and their components. By deploying a high-performance, multi-channel data acquisition system combining the DE-924U and DE-928U models, the project successfully captured critical dynamic response data. This solution provided the client with the necessary insights for structural analysis, fatigue evaluation, and design validation.
1. Project Background & Overview
Client & Objective: A technology group aimed to conduct a comprehensive dynamic analysis of aero-engine assemblies and sub-components. The primary objective was to measure and analyze their vibration and strain responses under operational or simulated conditions to assess structural integrity, identify resonant frequencies, and prevent fatigue failures.
Testing Scope: The testing likely covered a range of scenarios, from bench tests of individual components (like blades or brackets) to tests on larger sub-assemblies, requiring a flexible and scalable data acquisition solution.
Solution: A robust 64-channel dynamic signal acquisition system was implemented, configured with two distinct models to balance performance and channel density effectively.
2. Core Solution & Technical Highlights
The solution leveraged a hybrid system architecture to meet the demanding requirements of advanced dynamic testing.
1. High-Performance, Hybrid System Configuration:
High-Density Acquisition (DE-924U): The 32-channel DE-924U Dynamic Signal Test and Analysis System served as the high-channel-count backbone of the setup, efficiently accommodating a large number of sensors (e.g., strain gauges or accelerometers) for wide-area coverage on the test article.
Premium Performance Acquisition (DE-928U): The 32-channel DE-928U High-Performance Dynamic Signal Test and Analysis System was utilized for measurements requiring the highest possible accuracy, dynamic range, or anti-aliasing protection. This might have been reserved for critical measurement points or for signals with a very wide frequency range.
2. Comprehensive Dynamic Parameter Measurement:
Vibration Analysis: Integrated IEPE accelerometers to measure vibration acceleration, velocity, and displacement across the engine components, crucial for modal analysis and vibration qualification.
Strain Analysis: Utilized strain gauges to measure dynamic strain, enabling stress calculation and fatigue life prediction under cyclic loading.
3. Unified Software Platform:
Synchronized Operation: Both the DE-924U and DE-928U systems operated under the Dynatronic software platform, ensuring all 64 channels were perfectly synchronized for accurate cross-channel analysis (e.g., transfer functions, coherence).
Advanced Analysis: The software provided tools for real-time frequency domain analysis, order tracking, and modal analysis, allowing engineers to gain immediate insights from the acquired data.
4. Analysis of Key Success Factors
Optimal Resource Allocation: The combination of the DE-924U and DE-928U demonstrated a strategic approach, balancing cost-effectiveness for high-channel-count needs with top-tier performance for critical measurements.
System Scalability and Flexibility: The modular nature of the solution allowed the client to configure the system for various test articles, from small components to larger assemblies, making it a versatile asset for their lab.
Data Accuracy and Reliability: The high performance of the DE-928U, coupled with the solid functionality of the DE-924U, ensured the acquisition of clean, reliable data essential for making confident engineering decisions.
5. Project Significance & Value
Value for the Client (Technology Group): The testing system enabled:
Design Validation and Optimization: Verifying that components meet design specifications and identifying areas for improvement.
Root Cause Analysis: Diagnosing vibration or failure issues in existing designs.
Enhanced R&D Capability: Providing a powerful platform for future research and development activities in propulsion technology.
Value for Our Company: This project exemplifies our ability to provide tailored, hybrid solutions for complex dynamic testing needs. It showcases the flexibility of our product portfolio to meet specific performance and budgetary requirements within a single, integrated setup.
6. Conclusion & Outlook
The successful implementation of this 64-channel vibration and strain test system highlights our role as a provider of versatile and high-fidelity solutions for aerospace R&D.
Looking forward, this case suggests strategic opportunities:
Promote Hybrid System Benefits: Use this case to demonstrate how mixing system models can optimize performance and cost for clients with diverse measurement needs.
Target Component Testing Labs: This solution is ideal for R&D departments and testing laboratories focused on component-level validation. Marketing efforts can be directed towards these segments.
Develop Application-Specific Templates: Create pre-configured software settings and reporting templates for common component tests (e.g., modal survey, strain gage rosette analysis) to speed up client implementation.
