RU2551245C1 - Turbojet engine operation method and turbojet engine operated using this method - Google Patents

Abstract

FIELD: engines and pumps.

SUBSTANCE: invention relates to air-engine building. In TJE operation method before each start of the engine it is checked for readiness to operation, started, warmed up and ramped-up to the operating modes provisioned by regulations, it is stopped, periodically subjected to routine inspections and service of modules, assemblies and communication systems. At the final stage of capital repairs after assembly the engine is tested according to the multi-cycle program comprising the alternation of modes when performing stages of test by duration of TJE operation. Full scope of tests is formed, including a quick change of cycles in the complete register from quick selection of maximum or full augmented power mode till complete stop of the engine, and then, representative cycle of continuous operation with multiple alteration of modes in the whole working spectrum with various span of range of the mode change, which exceeds the flight time at least 5 times.

EFFECT: improvement of correctness and expansion of representativeness of assessment of resource and reliability of operation of the engine after capital repairs and providing the increased post-repair resource of the engine in conditions of flight operation of TJE by high-manoeuvrable planes.

5 cl, 1 dwg

Description

The invention relates to the field of aircraft engine manufacturing, and in particular to methods of operating aircraft turbojet engines.

Known dual-circuit, twin-shaft turbojet engine (turbojet engine), including turbocompressor complexes, one of which contains a compressor and a low pressure turbine mounted on one shaft, and the other contains a compressor and a high pressure turbine, an intermediate separation housing similarly combined on the other shaft, coaxial with the first between the mentioned compressors, external and internal circuits, the main and afterburner combustion chambers, a chamber for mixing gas-air flows of the working fluid and an adjustable nozzle (N.N.Siro tin et al. Fundamentals of designing the production and operation of aircraft gas turbine engines and power plants in the CALS technology system. Book 1. M .: Nauka, 2011, pp. 41-46, Fig. 1.24).

A well-known turbojet engine, which is double-circuit, contains a housing supported by compressors and turbines, a cooled combustion chamber, a fuel-pump group, jet nozzles, and a control system with command and executive bodies (Shulgin V.A., Gaysinsky S.Ya Dual-circuit turbojet engines of low-noise aircraft. M: Mashinostroenie, 1984, pp. 17-120).

A known method for the development and testing of aircraft engines such as turbojet, including the development of specified modes, parameter monitoring and evaluation of resource and reliability of the engine. In order to reduce the test time during engine refinement of 10-20%, tests are carried out with the gas temperature in front of the turbine exceeding the maximum operating temperature by 45-65 ° C (SU 1151075 A1, publ. 10.08.2004).

There is a method of testing a turbojet engine to determine the resource and reliability, which consists in the alternation of modes when performing stages lasting longer than the flight time. The engine is tested in stages. The duration of non-stop work at the stand and the alternation of modes are set depending on the purpose of the engine (L.S. Skubachevsky. Test of jet engines. M: Mashinostroenie, 1972, p.13-15).

A known method of operation and repair of a turbojet engine in technical condition. The operation of the engine according to its technical condition is based on technical diagnostics as a means of obtaining objective information about the state of a particular engine. This means that the actual technical condition of almost all engine components, assemblies and systems can be estimated with a certain frequency and accuracy by changing their parameters (NN Sirotin et al. Fundamentals of designing the production and operation of aircraft gas turbine engines and power plants in the CALS technology system Book 1. M.: Science, 2011, pp. 44-50).

The disadvantages of these known technical solutions are the increased labor and energy intensity of the tests and the insufficiently high estimate of the resource and reliability of the engine in a wide range of flight modes and operating conditions due to the inadequacy of the program for bringing specific test results to the results referred to standard engine operating conditions by known methods that are not with sufficient accuracy take into account changes in the parameters and operating modes of the engine. This complicates the possibility of bringing the experimental test parameters to parameters that are as close as possible to the real structure and the specific ratio of the engine operating modes during operation.

The task of the group of inventions related by a single creative concept is to develop a method of operating a turbojet engine and a turbojet engine operated by the claimed method with improved performance and increased reliability of the experimentally tested engine life and reliability after overhaul in conditions as close as possible to the real structure and specific ratio of modes engine operation during post-repair operation at high-altitude rennyh aircraft.

The problem is solved in that in the method of operation of a turbojet engine according to the invention, before each engine start, performed by double-circuit, two-shaft, check the engine is ready for operation, start, warm up and bring the engine to operating modes specified in the regulations, the engine is stopped, preventive measures are periodically performed Inspections and maintenance of modules, assemblies and communication systems, including low-pressure compressor (LPC) with an input guide vane, between weft guides and output straightening apparatus; gas generator units - high pressure compressor (HPC); an intermediate casing connecting said compressors; inspect the body of the main combustion chamber (ACS) and, if necessary, inspect the body and nozzle system of the ACS heat pipe; and also inspecting, preferably sixty-four tubular block modules of the ring air-air heat exchanger; periodically inspect a high-pressure turbine (HPT) having a nozzle apparatus, a rotor with a shaft and at least one impeller; inspect the engine mounts, inspect the low pressure turbine (LP), and also inspect the mixer, front-end device and the afterburner combustion chamber, jet nozzle; a box of drives of service engine units; inspect and, if necessary, test the electrical, air, hydraulic fuel and oil systems, in addition? periodically check the status of command blocks, actuators and cables of monitoring systems and automatic engine control; periodically carry out the current and at least one major repairs provided for by the regulations, during which they conduct an external inspection and install the engine on the test bench, check for defects and move the engine to the assembly shop, in which the external communications are dismantled and the engine is disassembled at functional modules, units and assembly units; disassembly, washing, condition monitoring and fault detection of modules, assemblies and parts, referral to mechanical assembly / mechanical posts with the implementation of restoration repair, structural and technological refinement or post-defective replacement of parts with new ones; acquisition of newly-repaired and new parts and assembly units, assembly and workshop testing of units, modules and engine assembly; moreover, the engine is tested according to a multi-cycle program, including the alternation of modes during the test stages with a turbojet engine operating longer than the programmed flight time, according to the program, typical flight cycles are formed before the tests and the damageability of the most loaded parts is determined, based on this, the required number of loading cycles is determined during the test, and then form and produce the full scope of tests, including the execution of a sequence of test cycles - fast reaching the maximum or full forced mode, quick reset to the “low gas” mode, stopping and a long-term operation cycle with multiple alternating modes in the entire operating spectrum with a different range of changes in the operating modes of the turbojet engine, which in aggregate exceeds the flight time by 5-6 times at the same time, a different range of changes in the engine operating modes is realized by changing the level of the gas differential in specific test modes from initial to maximum - maximum or full forced mode operation of the engine by transferring the initial reference point when the corresponding mode is performed, taking the latter in one of the modes in the position corresponding to the “low gas” level, and in other modes - in intermediate or final positions corresponding to different percentages or the full value of the maximum gas level or a full forced mode, moreover, a quick exit to the maximum or forced modes on part of the test cycle is carried out at a rate of throttle response, followed by reset.

At the same time, when starting the engine for repair and preparing parts for applying restoration coatings, they can perform chemical, ultrasonic washing and / or sandblasting of parts, micrometric measurements and determination of strength by non-destructive testing and rejection of defective parts.

In the process of engine overhaul, the application of reconditioning coatings to parts can be optionally performed by chromium plating, galvanizing, cadmium plating, copper plating, oxidizing, aluminizing, oxide phosphating, silver plating, chemical nickel plating, passivation and / or applying coatings.

The application of reconditioning coatings to parts during the overhaul to increase the wear resistance of surfaces of reconditioned parts, if necessary, can optionally be performed by electrospark alloying of surfaces, detonation or plasma spraying of powder composites.

The problem in terms of a turbojet engine is solved by the fact that the turbojet engine according to the invention is subject to operation as described above.

The technical result provided by the group of inventions related by a single creative idea is to develop a method of operation and exploited by the claimed method of turbofan engines with an experimentally verified resource, as well as with increased reliability of turbofan engines in the process of after-sales operation. Improving the reliability of the results of tests carried out after the overhaul of an operated turbojet engine is achieved due to the alternation of modes developed in the invention when performing test phases that are 5-6 times longer than the programmed flight time. At the same time, typical flight cycles are clarified, on the basis of which the damage to the most loaded parts is determined according to the program. Based on this, the required number of loading cycles during the test is determined, including the quick change of cycles in the full register from the quick exit to the maximum or full forced mode to the complete stop of the engine and then a representative long-term operation cycle is formed in the post-repair period with multiple alternating modes in the entire operating spectrum with a different range of modes. This makes it possible to increase the correctness and expand the representativeness of the assessment of the resource and reliability of the engine after overhaul and provides increased after-repair engine life in the conditions of flight operation of turbojet engines on highly maneuverable aircraft.

The invention is illustrated in the drawing (figure 1), which shows a turbojet engine, a longitudinal section.

The method of operation of the turbojet engine is as follows.

Before each start-up of a turbojet engine made by double-circuit, two-shaft, check the readiness of the engine for work. Start, warm up and output the engine to the operating modes stipulated by the regulations, and then stop the engine. Periodically, preventive examinations and maintenance of the modules, components and communication systems are performed, including a low-pressure compressor 1 with an inlet guide apparatus 2, intermediate guide apparatus 3 and an output rectifier apparatus 4; gas generator units - high pressure compressor 5; connecting the KND and KVD the intermediate case. Inspect the body of the main combustion chamber 6 and, if necessary, inspect the body and nozzle system of the flame tube of the ACS. An inspection is also made of, preferably, of sixty-four tubular block modules of an annular air-air heat exchanger 7. A high-pressure turbine 8 having a nozzle apparatus, a rotor 9 with a shaft and at least one impeller is periodically inspected. Inspect the engine mounts, inspect the turbine 10 low pressure. Also inspect the mixer, front-end device and the afterburner combustion chamber, jet nozzle 11, the box of drives of service engine units. Inspect and, if necessary, test the electrical, air, hydraulic fuel and oil systems.

Besides? periodically check the status of command blocks, actuators and cables of monitoring systems and automatic engine control. Periodically carry out current repairs provided for in the regulations, as well as at least one overhaul.

In the process of overhaul, an external inspection and installation of the engine on the test bench is carried out, defects are checked, and the engine is moved to the assembly shop, in which the external communications are dismantled and the engine is disassembled into functional modules, units and assembly units. They disassemble, flush, monitor the condition and detect the modules, components and parts, referral to mechanical assembly / mechanical posts with the implementation of restoration repair, structural and technological refinement or post-defective replacement of parts with new ones. Then they complete the newly-repaired and new parts and assembly units, assemble and carry out workshop tests of units, modules, and assemble the engine.

At the final stage of the overhaul after assembly, the engine is tested, if necessary, post-repair tuning is performed, during which tests of the repaired engine are performed. The engine is tested according to a multi-cycle program, including the alternation of modes during the execution of the test stages with a turbojet operation duration exceeding the programmed flight time. According to the program, pre-tests specify and form typical flight cycles and determine the damage to the most loaded parts. Based on this, the required number of loading cycles during the test is determined. Then the full scope of tests is formed and performed, including the execution of a sequence of test cycles - quick exit to the maximum or full forced mode, quick reset to the "low gas" mode, stop. A long cycle of work is also carried out with multiple alternating modes in the entire working spectrum with a different range of variation of the turbojet engine operating modes, which in aggregate exceeds the flight time by 5-6 times. A different range of changes in the engine operating modes is realized by changing the level of the gas differential in specific test modes from initial to maximum - maximum or full forced engine operation by transferring the initial reference point when performing the corresponding mode, taking the latter in one of the modes in a position corresponding to the level " low gas ”, and in other modes - in intermediate or final positions corresponding to different percentages or the full value of the gas level maximum or full forced mode. A quick exit to the maximum or forced modes on the part of the test cycle is carried out at the rate of throttle response, followed by reset.

When starting the engine for repair and preparing parts for applying restoration coatings, chemical, ultrasonic washing and / or sandblasting of the parts, micrometric measurements and determination of strength by non-destructive testing and rejection of defective parts are performed.

In the process of engine overhaul, the application of reconditioning coatings to parts is optionally performed by chromium plating, galvanizing, cadmium plating, copper plating, oxidizing, aluminizing, oxide phosphating, silver plating, chemical nickel plating, passivation and / or applying coatings.

The application of reconditioning coatings to parts during the overhaul process to increase the wear resistance of surfaces of reconditioned parts, if necessary, is optionally carried out by electrospark alloying of surfaces, detonation or plasma spraying of powder composites.

The turbojet is subjected to operation as described above.

An example of the implementation of the turbojet test on a multi-cycle program.

The test is subjected to turbojet engines with a given resource of 500 hours of total operating time after the first overhaul. In the indicated resource, the operating time is set to 20 hours at maximum mode, of which 5 hours at full forced mode. Typical flight cycles (TFCs) are formed and a predetermined engine operating time of 1 h is set, which is equivalent to the flight time of an aircraft (LA) according to the adopted TOC. Based on the fuel processing center, the damage to the most loaded parts is determined by calculation. On the basis of this, the required equivalent damage number of cycles during the tests is determined. In this embodiment, the following set of load test cycles is taken - performing 700 (400 + 300) starts with reaching the maximum and forced modes, respectively, as well as 400 pick-ups from the “low gas” (MG) mode to the maximum (Max) and 300 from mode 0 , 8 Max before the forced (For) mode.

Set the safety factor for the required number of test load cycles and operating hours K = 1.2.

Form the full scope of life tests and develop a test program:

1. The total operating time during the life tests is 500 · 1.2 = 600 hours, of which the maximum operating time is (20-5) · 1.2 = 18 hours, and in the forced mode 5 · 1.2 = 6 hours .

2. Take the duration of the test phase 5 hours, and determine the number of five-hour steps 600: 5 = 120.

3. Set the number of starts taking into account the safety factor of 700 · 1.2 = 840, as well as from MG to Max 400 · 1.2 = 480 and from 0.8 Max to Fore 300 · 1.2 = 360.

4. Each five-hour stage includes 840: 120 = 7, pick-ups from the MG mode to Max 480: 120 = 4 and pick-ups from the 0.8 Max mode to Fore 360: 120 = 3, as well as the operating time at maximum and forced modes 18 · 60 : 120 = 9 minutes 360: 120 = 3 min.

5. Set the sequence of test cycles: quick exit to the maximum or full forced mode, quick reset to MG mode and stop. Then, a long-term operation cycle is provided with multiple alternation of load cycles with a range of regime change ranges from MG to Max and 0.8 Max to For within the range of the test stages established above.

Perform tests of turbofan engines according to the specified program. Then, the engine is defecated and the test results are analyzed, according to which a decision is made on recognizing the engine as having passed the tests after major repairs.

Claims (5)

 1. The method of operation of a turbojet engine (turbojet engine), characterized in that before each start of the engine, performed double-circuit, twin-shaft, check the readiness of the engine for work, start, warm up and bring the engine to operating modes specified in the regulations, engine shutdown, periodically produce routine inspections and maintenance of modules, assemblies and communication systems, including a low-pressure compressor (LPC) with an input guide vane, intermediate guides and an exit hydrochloric flow straightener; gas generator units - high pressure compressor (HPC); an intermediate casing connecting said compressors; inspect the body of the main combustion chamber (ACS) and inspect the body and nozzle system of the combustion tube ACS; as well as inspection of the sixty-four tubular block modules of the ring air-air heat exchanger; periodically inspect a high-pressure turbine (HPT) having a nozzle apparatus, a rotor with a shaft and at least one impeller; inspect the engine mounts, inspect the low pressure turbine (LP), and also inspect the mixer, front-end device and the afterburner combustion chamber, jet nozzle; a box of drives of service engine units; inspect and test electric, air, hydraulic fuel and oil systems, in addition, periodically check the status of command blocks, actuators and cables of monitoring and automatic engine control systems; periodically carry out the current and at least one major repairs provided for by the regulations, during which they conduct an external inspection and install the engine on the test bench, check for defects and move the engine to the assembly shop, in which the external communications are dismantled and the engine is disassembled at functional modules, units and assembly units; disassembly, washing, condition monitoring and fault detection of modules, assemblies and parts, referral to mechanical assembly / mechanical posts with the implementation of restoration repair, structural and technological refinement or post-defective replacement of parts with new ones; acquisition of newly-repaired and new parts and assembly units, assembly and workshop testing of units, modules and engine assembly; moreover, the engine is tested according to a multi-cycle program, including the alternation of modes during the test stages with a turbojet engine operating longer than the programmed flight time, according to the program, typical flight cycles are formed before the tests and the damageability of the most loaded parts is determined, based on this, the required number of loading cycles is determined during the test, and then form and produce the full scope of tests, including the execution of a sequence of test cycles - fast reaching the maximum or full forced mode, quick reset to the “low gas” mode, stopping and a long-term operation cycle with multiple alternating modes in the entire operating spectrum with a different range of changes in the operating modes of the turbojet engine, which in aggregate exceeds the flight time by 5-6 times at the same time, a different range of changes in the engine operating modes is realized by changing the level of the gas differential in specific test modes from initial to maximum - maximum or full forced mode operation of the engine by transferring the initial reference point when the corresponding mode is performed, taking the latter in one of the modes in the position corresponding to the “low gas” level, and in other modes - in intermediate or final positions corresponding to different percentages or the full value of the maximum gas level or a full forced mode, moreover, a quick exit to the maximum or forced modes on part of the test cycle is carried out at a rate of throttle response, followed by reset. 2. The method of operating a turbojet engine according to claim 1, characterized in that when starting the engine for repair and preparing the parts for applying restoration coatings, chemical, ultrasonic washing and / or sandblasting of the parts, micrometric measurements and determination of strength by non-destructive testing and rejection of defective details. 3. The method of operating a turbojet engine according to claim 2, characterized in that during the overhaul of the engine, the application of the restoration coatings to the parts is carried out optionally by chromium plating, galvanizing, cadmium plating, copper plating, oxidation, aluminizing, oxide phosphating, silver plating, chemical nickel plating, passivation and / or by applying coatings. 4. The method of operating a turbojet engine according to claim 2, characterized in that the application of reconditioning coatings to the parts during the overhaul to increase the wear resistance of the surfaces of the reconditioned parts is optionally performed by electrospark alloying of the surfaces, detonation or plasma spraying of powder composites. 5. A turbojet engine, characterized in that it is subject to operation according to any one of claims 1 to 4.

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