FBO Test of A Commercial Aero-Engine
This case analyzes a Fan Blade Out (FBO) simulation test conducted by a Shanghai-based commercial aero-engine company. The test focused on measuring the dynamic strain on a propeller (fan) rotating in a vacuum environment. A sophisticated wireless telemetry system was successfully deployed to capture critical data from the rotating assembly in real-time, demonstrating a solution to one of the most challenging scenarios in propulsion testing.
1. Project Background & Overview
Client & Objective: A leading commercial aero-engine company in Shanghai required to validate the structural integrity of a propeller under extreme conditions. The specific objective was to measure the dynamic strain on the propeller blades while rotating in a vacuum chamber, simulating a key aspect of a Fan Blade Out (FBO) test environment.
Core Challenge: Measuring data on a high-speed rotating component inside a vacuum chamber eliminates the possibility of using wired solutions or standard wireless telemetry that relies on atmospheric conditions.
Solution: A specialized in-vacuum wireless telemetry system was employed. Data acquisition modules were mounted directly on the rotating shaft to capture and transmit strain data wirelessly to an external receiver.
2. Core Solution & Technical Highlights
The solution's innovation lies in its ability to operate and transmit data within the challenging vacuum environment.
1. On-Board Wireless Telemetry for Vacuum:
Strain Measurement: Strain gauges were precisely bonded to the propeller blades to measure dynamic deformations caused by centrifugal and aerodynamic forces.
Vacuum-Compatible Hardware: Six WW-844DN wireless data acquisition nodes were fixed directly onto the rotating shaft. These modules are designed to operate in vacuum conditions, where traditional cooling is limited, and radio wave propagation differs.
Real-Time Data Transmission: The nodes digitized the strain gauge signals on the shaft and transmitted the data wirelessly through the vacuum chamber wall to an external base station and computer.
2. Real-Time Monitoring and Analysis:
Instantaneous Data Access: The system enabled real-time display and storage of dynamic strain data on a computer, allowing engineers to monitor the structural behavior of the propeller instantaneously during the test.
Critical for Validation: This real-time capability is crucial for ensuring test safety and for making immediate go/no-go decisions during such a high-energy test.
3. Analysis of Key Success Factors
Overcoming Extreme Environmental Challenges: The successful use of wireless telemetry within a vacuum environment represents a significant technical achievement, overcoming limitations of traditional measurement methods.
System Reliability: The robustness of the WW-844DN nodes under high G-forces, in a vacuum, and potentially at extreme temperatures was critical to the test's success.
Data Integrity: The system provided high-fidelity, real-time data essential for validating engine containment models and rotor dynamics post a blade-off event.
4. Project Significance & Value
Value for the Client (Engine Company): The test provided invaluable data to:
Verify Containment Design: Confirm that the engine casing can contain a liberated blade and that the remaining rotor system remains stable.
Meet Certification Requirements: Generate essential data required by aviation authorities (like CAAC and FAA) for engine certification.
De-risk Development: Identify potential issues early in the design process, reducing development risk and cost.
Value for Our Company: This project is a flagship demonstration of our capability in ultra-demanding propulsion testing environments. It positions our technology as a critical enabler for the most stringent safety certification tests in the aerospace industry.
5. Conclusion & Outlook
The successful execution of this FBO-related test underscores our leadership in providing data acquisition solutions for the most critical and challenging validation scenarios in aerospace.
Looking forward, this case provides a strategic outlook:
Establish as a Certification Testing Leader: Leverage this case to engage with all major engine OEMs globally, highlighting our proven solution for mandatory certification testing.
Focus on Extreme Environment Testing: Continue R&D to further enhance capabilities for in-vacuum, high-temperature, and high-G measurement applications.
Develop Integrated Safety-Critical Systems: Explore opportunities to integrate our data systems with test facility controls for enhanced safety monitoring and automated shutdown protocols during extreme tests.
