Multi-Parameter Engine Testing & Monitoring Solution

1. Project Background and Challenges

In May 2024, an aviation research institute aimed to enhance the performance, reliability, and service life of an Il-76 transport aircraft engine. Comprehensive monitoring of key parameters such as temperature, pressure, corrosion, vibration, and stress under various operating conditions was required. The core challenges of the test included:

• Multi-parameter synchronous monitoring: Simultaneous acquisition of vibration, pressure, speed, and other multidimensional data with high-precision time synchronization.

• Real-time requirements: Real-time monitoring of engine status during testing to promptly detect anomalies and make decisions.

• Environmental adaptability: The engine test bed featured strong electromagnetic interference, high temperatures, and high vibration levels, demanding extreme equipment reliability.

2. Solution: Dynatronic Dynamic Signal Acquisition System

The project utilized the Dynatronic Dynamic Signal Acquisition System as the core data acquisition device, building a complete multi-parameter integrated testing and real-time monitoring system.

System Configuration and Integration:

• Sensor Layout:

  • 10 acceleration sensors: Installed on the engine casing, bearing seats, and critical connection points to monitor radial and axial vibration.

  • 4 pulsating pressure sensors: Mounted at the compressor outlet and turbine inlet to capture dynamic pressure fluctuations.

  • 2 speed sensors: Monitored high-pressure and low-pressure rotor speeds, precisely correlating vibration and pressure data.

• Data Acquisition Equipment:

  • The Dynatronic Dynamic Signal Acquisition System supported 16-channel synchronous acquisition with a maximum sampling rate of 200 kS/s and 24-bit resolution.

  • Built-in anti-aliasing filters and signal conditioning capabilities enabled direct connection to IEPE acceleration sensors and voltage-type pressure sensors.

• Real-Time Data Processing and Transmission:

  • Dedicated software provided real-time data display, time/frequency domain analysis, and alarm threshold settings.

  • Data streams were transmitted in real time to a remote monitoring center via UDP protocol with a latency of less than 50 ms.

System Features:

• High-Precision Synchronization: All channels employed synchronous sampling technology with a phase error of less than 0.1°, ensuring precise correlation between vibration and pressure data.

• Strong Anti-Interference Capability: The system complied with military-standard electromagnetic compatibility requirements, ensuring stable operation in high-interference test bed environments.

• Flexibility and Scalability: Supported cascading of multiple devices to meet future channel expansion needs.

3. Testing Process and Data Value

Test Execution

• Tests were conducted under multiple operating conditions, including idle, cruise, maximum continuous thrust, and takeoff thrust.

• Real-time monitoring of vibration velocity, acceleration spectrum, pressure pulsation, and speed parameters was performed.

Key Data Results

• Vibration Analysis:

  • A resonance peak was identified near 90% speed of the high-pressure rotor, mitigated by adjusting support stiffness.

  • Total vibration values were below the ISO 10816 standard limits, validating engine balance performance.

• Pressure Pulsation Analysis:

  • The pressure pulsation amplitude at the compressor outlet was less than 5% of the design value, indicating excellent aerodynamic stability.

  • No rotating stall characteristic frequencies were detected in the turbine inlet pressure spectrum.

• Multi-Parameter Correlation Analysis:

  • Synchronized analysis of vibration and pressure data pinpointed abnormal vibrations originating from specific pressure fluctuation frequencies.

Decision-Making Support Value

• Real-time data transmission via UDP to the monitoring center enabled remote collaborative analysis by technical support teams.

• Engine control logic was optimized based on test results, extending overhaul intervals by 20%.

• Data provided support for subsequent engine design improvements, reducing the number of test iterations.

4. Customer Benefits

• All-in-One Testing Platform:
  The Dynatronic acquisition system integrated signal conditioning, acquisition, and real-time transmission functions, simplifying system architecture and reducing deployment costs.

• Real-Time Monitoring and Remote Collaboration:
  UDP data streams supported multi-terminal access, enabling remote expert collaboration and improving problem response speed.

• High-Reliability Assurance:
  The system operated stably in harsh environments with a 100% data integrity rate, meeting aviation-grade testing standards.
  
  5. Application Prospects

This solution has been successfully applied to Il-76 engine testing and can be extended to the following scenarios:

• Civil Aircraft Engine Health Management (EHM) Systems;

• Gas Turbine Fault Diagnosis and Predictive Maintenance;

• UAV Power System Testing.