Case Study Report: RE-846U Aero-Engine Surge Test
This case study analyzes a project in which an aviation university utilized a 16-channel RE-846U Rugged Data Acquisition System to conduct vibration testing on surge phenomena in a certain type of aero-engine. The test aimed to capture the dynamic vibration characteristics during engine surge by using highly reliable data acquisition, providing data support for researching surge mechanisms and developing prevention and control measures. The case highlights the system's stability and accuracy under harsh operating conditions.
1. Project Background & Objectives
Test Background: Surge is an unstable operating condition of the compressor that can lead to severe engine vibration or even structural damage. Studying surge characteristics is crucial for engine safety.
Test Objectives: To analyze the surge trigger conditions, characteristic vibration frequencies, and amplitude variations by measuring vibration signals at critical engine locations during the surge process.
Technical Challenges: Surge conditions involve high temperatures, high pressures, and strong vibrations, requiring data acquisition equipment with high reliability, anti-interference capability, and dynamic response characteristics.
2. Solution & Technical Highlights
1. Dedicated Data Acquisition System
RE-846U Rugged Acquisition System: The 16-channel RE-846U system was employed. Its rugged design is suitable for the high-temperature, high-vibration environment of the engine test bed, ensuring continuous and accurate data acquisition.
Synchronized Vibration Measurement: The system supports multi-channel synchronous acquisition, accurately capturing the phase relationships and vibration transfer paths between different measurement points during surge.
2. Sensor Configuration & Data Analysis
Vibration Sensor Layout: Accelerometers were placed at key locations such as the compressor casing and bearing housing to monitor the broad-frequency vibration response induced by surge.
Surge Characteristic Identification: Time-domain waveform and frequency spectrum analysis were used to identify the low-frequency oscillations (typically 1–10 Hz) and high-frequency harmonic components characteristic of surge.
3. Key Success Factors
Environmental Adaptability: The ruggedness of the RE-846U ensured stable operation under strong vibration and electromagnetic interference.
High Dynamic Range Acquisition: The system's high sampling rate (capable of reaching hundreds of kHz) effectively captured the details of the transient surge process.
Real-time Monitoring Capability: Real-time display of vibration data during the test allowed for timely adjustment of operating conditions and prevention of equipment overload.
4. Project Value & Significance
Value for the Client:
Provided high-credibility data for surge mechanism research, supporting improvements in engine aerodynamic stability design.
Helped the university establish a research platform for engine fault simulation and safety early warning.
Value for Our Company:
Demonstrated the technical advantages of the RE series products in extreme conditions, strengthening competitiveness in the aviation research market.
Provided a standardized solution for engine testing, which can be promoted to other universities and research institutes.
5. Conclusion & Outlook
This project successfully achieved precise measurement of the vibration characteristics of an aero-engine during surge using the RE-846U system, verifying its applicability in aviation propulsion research. Future directions for expansion include:
Multi-parameter Integration: Adding pressure and temperature sensors to synchronously analyze the coupling mechanism of aerodynamic and structural responses.
Predictive Algorithm Development: Building surge early warning models based on the acquired data to enhance engine active control capabilities.
Industry-Academia-Research Collaboration: Using such projects as benchmarks to deepen cooperation with aviation universities in the field of fault diagnosis.
