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Auto-updating model-based control for thrust variation mitigation and acceleration performance enhancement of gas turbine aero-engines

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Propulsion and Power Research 2024年第3期13卷 394-415页

作者： Zhiyuan Wei Shuguang Zhang Research institute of aero-engine Beihang UniversityBeijing 102206China Beihang University Beijing 102206China Aircraft/engine Integrated system Safety Beijing Key Laboratory Beihang UniversityBeijing 102206China

Model-based control shows promising potential for engine performance improve-ment and future aero-propulsion *** this paper,an auto-updating thrust variation mitigation(AuTVM)control approach using on-board model strategies is proposed for gas tur-bine aero-engines under in-service degradation effects,which aims at active thrust regulation and acceleration protection in a simultaneous *** AuTVM control is integrated with an on-line block,based on a reliable on-board engine model,and an off-line part for the periodical update of control parameters via post-flight engine monitoring *** core feature of the AuTVM control is a set of auto-updating loops within the on-line part,including thrust regu-lation loop,surge margin loop,turbine entry temperature loop,and the steady loop,whose con-trol parameters are periodically adjusted with increasingflight ***,an industrial sensor-based baseline controller and two tailored model-based controllers,i.e.,a thrust variation mitigation(TVM)controller withfixed gains and a self-enhancing active transient protection(SeATP)controller with pro-active transient protection and passive thrust control,are also developed as comparison *** simulations for idle to full-power acceleration tests are carried on a validated aero-thermal turbofan engine model using publicly available degra-dation *** results demonstrate that both new engines and severely degraded en-gines regulated by the AuTVM controller show significant thrust response enhancement,compared to the baseline ***,thrust variation at the maximum steady state of degraded engines,which exists within the SeATP controller and the baseline controller,is suppressed by the proposed AuTVM *** analysis against degradation uncer-tainties and sensor accuracy confirms that the AuTVM controller owns a closer maximum steady-state thrust distribution to the desired value than those of the SeATP and the basel

关键词： Gas turbine aero-engines Auto-updating thrust variation mitigation Active transient protection Model-based control engine performance improvement Degradation effects

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An optimized time-adaptive aerothermal coupling calculation method for aerothermal analysis of disc cavity system

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Chinese Journal of aeronautics 2024年第9期37卷 164-177页

作者： Shuai BI Junkui MAO Lei WANG Feng HAN College of Energy and Power engineering Nanjing University of Aeronautics and AstronauticsNanjing 20016China aecc aeroengine control system institute Wuxi 214063China Integrated Energy institute Nanjing University of Aeronautics and AstronauticsNanjing 210016China

In order to further achieve the balance between the calculation accuracy and efficiency of the transient analysis of the aero-engine disc cavity system,an Optimized Time-adaptive aerother-mal Coupling calculation(OTAC)method has been *** combines one-dimensional tran-sient calculation of air system,Conventional Sequence Staggered(CSS)method,Time-adaptive aerothermal Coupling calculation(TAC)method and differential evolution optimization algorithm to obtain an efficient and high-precision aerothermal coupling calculation method of air *** both the heat conduction in the solid domain and the flow in the fluid domain as unsteady states in the OTAC,the interaction of fluid-solid information within a single coupling time step size was implemented based on the CSS ***,the coupling time step size was automatically adjusted with the number of iterations by using the Proportional-Integral-Deri vative(PID)*** show that when compared with the traditional loosely coupling method with a fixed time step size,the computational accuracy and efficiency of the OTAC method are improved by 8.9%and 30%,*** with the tight coupling calculation,the OTAC method can achieve a speedup of 1 to 2 orders of magnitude,while the calculation error is maintained within 6.1%.

关键词： Air system 1D-3D coupling Conjugate heat transfer Transient calculation Adaptive time step size

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Machining fixture for adaptive CNC machining process of near-net-shaped jet engine blade

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Chinese Journal of aeronautics 2020年第4期33卷 1311-1328页

作者： Dongbo WU Hui WANG Jinsong PENG Kaiyao ZHANG Jie YU Xuesong ZHENG Yunhai CHEN State Key Laboratory of Tribology Beijing Key Lab of Precision/Ultra-Precision Manufacturing Equipment and ControlDepartment of Mechanical EngineeringTsinghua UniversityBeijing 100084China Yantai University Yantai 264005China aecc Xi’an aero-engine LTD Xi'an 710021China BEIJING POLYTECHNIC Beijing 100176China

Low stiffness and positioning problems are difficulties and challenges in the precise machining of near-net-shaped *** paper aims to achieve high accuracy in manufacturing by fixture-and deformation-control in the adaptive CNC machining *** CNC machining technology is first analyzed,and new fixture-evaluation criteria and methods to evaluate the adaptive CNC machining process fixture design are ***,a machining fixture is designed and manufactured after analyzing its positioning scheme,clamping scheme,materials(PEEK-GF30),and structure ***,the designed fixture is analyzed by FEA and experimentally verified by a cutting *** results show that the deformation of the blade is an overall rigid-body displacement,the main deformation of the blade-fixture system occurs on the four clamping heads,and this fixture can effectively protect the blade from local *** proposed clamping-sequence method reliably and effectively controls the local maximum deformation of the *** system stiffness is increased by 20 Hz,with each clamping force increased by 200 *** high-and low-frequency displacement in roughing milling or finishing milling are acceptable relative to the accuracy demand of blade *** fixture and an adaptive CNC machining process can achieve high accuracy in blade manufacturing.

关键词： Adaptive CNC machining process Clamping force Clamping sequence Fixture displacement response Machining fixture Near-net-shaped blade

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Design method of optimal control schedule for the adaptive cycle engine steady-state performance

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Chinese Journal of aeronautics 2022年第4期35卷 148-164页

作者： Yihao XU Hailong TANG Min CHEN School of Energy and Power engineering Beihang UniversityBeijing 100083China Research institute of aero-engine Beihang UniversityBeijing 102206China

The alternative working modes and flexible working states are the outstanding features of an adaptive cycle engine, with a proper control schedule design being the only way to exploit the performance of such an engine. However, unreasonable design in the control schedule causes not only performance deterioration but also serious aerodynamic stability problems. Thus, in this work,a hybrid optimization method that automatically chooses the working modes and identifies the optimal and smooth control schedules is proposed, by combining the differential evolution algorithm and the Latin hypercube sampling method. The control schedule architecture does not only optimize the engine steady-state performance under different working modes but also solves the control-schedule discontinuity problem, especially during mode transition. The optimal control schedules are continuous and almost monotonic, and hence are strongly suitable for a control system, and are designed for two different working conditions, i.e., supersonic and subsonic throttling,which proves that the proposed hybrid method applies to various working conditions. The evaluation demonstrates that the proposed control method optimizes the engine performance, the surge margin of the compression components, and the range of the thrust during throttling.

关键词： Adaptive cycle engine control schedule design Hybrid optimization method Mode transition Performance optimization

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Application of immersed boundary method in turbomachines

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Chinese Journal of aeronautics 2023年第5期36卷 268-279页

作者： Congcong CHEN Yuwei WANG Zhuo WANG Lin DU Xiaofeng SUN School of Energy and Power engineering Beihang UniversityBeijing 100191China Research institute of aero-engine Beihang UniversityBeijing 100191China

Simulating unsteady turbulent flow in turbomachines is still challenging due to the complexity of blade geometry and relative motion between rotor and *** study presents an Immersed Boundary Method(IBM)for high-Reynolds turbomachinery internal flows,and shows the advantage of the automatic grid generation techniques and flexible moving boundary *** wall functions are used in the present method to alleviate the wall resolution restriction of turbulence *** Two-Dimensional(2-D)IBM solver,which was previously developed and tested for a low-speed compressor,is further validated for a well-documented Low-Pressure Turbine(LPT)*** the blade loading and the total pressure losses in the wake are well captured by the present 2-D *** complex Three-Dimensional(3-D)effects in turbomachines motivate the further development of an extended 3-D IBM solver by using a curvilinear-coordinate system that facilitates the hub and casing boundary *** good performance of the 3-D solver is demonstrated through comparison with CFX solver solutions for the rotor configuration of Advanced Noise control Fan(ANCF).Further effects of the grid resolution on capturing the blade wake are *** results indicate that the present 3-D solver is capable of reproducing the evolution of the blade wake with suitable computational grid.

关键词： Immersed boundary method Turbomachinery Turbulence simulation Wake prediction Wall function

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Bifurcation control of nonlinear oscillator in primary and secondary resonance

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Journal of Central South University of Technology 2007年第6期14卷 826-831页

作者：李克安萧寒崔荣繁 Department of Mechanical and Electrical engineering Hunan Institute of Science and Technology College of Mechanics and aerospace Hunan University Shenyang Liming aero-engine (Group) Corporation

A weakly nonlinear oscillator was modeled by a sort of differential equation, a saddle-node bifurcation was found in case of primary and secondary resonance. To control the jumping phenomena and the unstable region of the nonlinear oscillator, feedback controllers were designed. Bifurcation control equations were obtained by using the multiple scales method. And through the numerical analysis, good controller could be obtained by changing the feedback control gain. Then a feasible way of further research of saddle-node bifurcation was provided. Finally, an example shows that the feedback control method applied to the hanging bridge system of gas turbine is doable.

关键词： nonlinear oscillator saddle-node bifurcation feedback controller primary resonance secondary resonance gas turbine

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Turbo-shaft engine adaptive neural network control based on nonlinear state space equation

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Chinese Journal of aeronautics 2024年第4期37卷 493-507页

作者： Ziyu GU Qiuhong LI Shuwei PANG Wenxiang ZHOU Jichang WU Chenyang ZHANG Jiangsu Province Key Laboratory of aerospace Power system Nanjing University of Aeronautics and AstronauticsNanjing 210016China aecc Hunan Aviation Powerplant Research institute Zhuzhou 412002China

Intelligent Adaptive control(AC) has remarkable advantages in the control system design of aero-engine which has strong nonlinearity and uncertainty. Inspired by the Nonlinear Autoregressive Moving Average(NARMA)-L2 adaptive control, a novel Nonlinear State Space Equation(NSSE) based Adaptive neural network control(NSSE-AC) method is proposed for the turbo-shaft engine control system design. The proposed NSSE model is derived from a special neural network with an extra layer, and the rotor speed of the gas turbine is taken as the main state variable which makes the NSSE model be able to capture the system dynamic better than the NARMA-L2 model. A hybrid Recursive Least-Square and Levenberg-Marquardt(RLS-LM) algorithm is advanced to perform the online learning of the neural network, which further enhances both the accuracy of the NSSE model and the performance of the adaptive controller. The feedback correction is also utilized in the NSSE-AC system to eliminate the steady-state tracking error. Simulation results show that, compared with the NARMA-L2 model, the NSSE model of the turboshaft engine is more accurate. The maximum modeling error is decreased from 5.92% to 0.97%when the LM algorithm is introduced to optimize the neural network parameters. The NSSE-AC method can not only achieve a better main control loop performance than the traditional controller but also limit all the constraint parameters efficiently with quick and accurate switching responses even if component degradation exists. Thus, the effectiveness of the NSSE-AC method is validated.

关键词： Adaptive control systems Turbo-shaft engine Neural network Nonlinear state space equation NARMA-L2

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Effect of PyC Interface Thickness on the Heat-stability of Cansas-ⅡSiC_(f)/SiC Composites

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Journal of Wuhan University of Technology(Materials Science) 2023年第4期38卷 725-734页

作者：韩笑于国强张盛 SHI Jian GAO Xiguang SONG Yingdong WANG Fang Key Laboratory of aero-engine Thermal Environment and Structure Ministry of Industry and Information TechnologyCollege of Energy and Power EngineeringNanjing University of Aeronautics and AstronauticsNanjing210016China College of Chemical engineering Nanjing Forestry UniversityNanjing210016China Jiangsu Province Key Laboratory of aerospace Power system College of Energy and Power EngineeringNanjing University of Aeronautics and AstronauticsNanjing210016China State Key Laboratory of Mechanics and control of Mechanical Structures Nanjing University of Aeronautics and AstronauticsNanjing210016China aecc Sichuan Gas Turbine Establishment Chengdu610500China

The effect of the pyrolytic carbon(PyC)interface thickness on the heat-stability of CansasⅡSiC_(f)/SiC composites under Ar up to 1500℃was studied in *** the heat treatment at 1500℃for 50 h,the interface bonding strength of the thin interface(about 200 nm)decreases from 74.4 to 20.1 MPa(73.0%),while that of the thick interface(about 2μm)declines from 7.3 to 3.2 MPa(52.7%).At the same time,the decline fraction of strength of the composites with the thin interface is 12.1%,less than that with the thick interface(42.0%).The fiber strength also decreases after heat treatment,which may be due to the significant growth ofβ-SiC grains and critical *** different heat-stability of the interface with the thin and thick thickness might be related to the inconsistency of the degree of the graphitization of *** with the composites with the thick interface,the composites with the thin interface remained higher tensile strength after heat treatment due to the better interface bonding *** interface with strong bonding strength could protect the fiber by postponing the decomposition of amorphous phases SiC_(x)O_(y) and hindering the generation of fiber defects.

关键词： SiC_(f)/SiC mini-composites heat-stability interface thickness mechanical properties microstructure

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Collaborative manufacturing technologies of structure shape and surface integrity for complex thin-walled components of aero-engine:Status,challenge and tendency

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Chinese Journal of aeronautics 2023年第7期36卷 1-24页

作者： Biao ZHAO Wenfeng DING Zhongde SHAN Jun WANG Changfeng YAO Zhengcai ZHAO Jia LIU Shihong XIAO Yue DING Xiaowei TANG Xingchao WANG Yufeng WANG Xin WANG College of Mechanical and Electrical engineering Nanjing University of Aeronautics and AstronauticsNanjing 210016China School of Mechanical engineering Northwestern Polytechnical UniversityXi’an 710072China AVIC Manufacturing Technology institute Beijing 100024China School of Mechanical Science and engineering Huazhong University of Science and TechnologyWuhan 430074China aecc Shenyang Liming aero-engine Co. LTD.Shenyang 110000China

Presently,the service performance of new-generation high-tech equipment is directly affected by the manufacturing quality of complex thin-walled components.A high-efficiency and quality manufacturing of these complex thin-walled components creates a bottleneck that needs to be solved urgently in machinery *** address this problem,the collaborative manufacturing of structure shape and surface integrity has emerged as a new process that can shorten processing cycles,improve machining qualities,and reduce *** paper summarises the research status on the material removal mechanism,precision control of structure shape,machined surface integrity control and intelligent process control technology of complex thin-walled *** solutions and technical approaches are then put forward to solve the critical problems in the high-performance manufacturing of complex thin-wall *** development status,challenge and tendency of collaborative manufacturing technologies in the high-efficiency and quality manufacturing of complex thin-wall components is also discussed.

关键词： Collaborative manufacturing of shape and performance Complex thin-walled component Intelligent process control Material removal mechanism Surface integrity

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Theoretical and numerical research on effect of tension mechanisms in strip flatness electromagnetic control rolling mills

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Journal of Iron and Steel Research International 2024年第9期31卷 2217-2235页

作者： Ting-song Yang Tie-heng Yuan Wen-quan Sun An-rui He Chun-tao Qu National engineering Research Center of Advanced Rolling and Intelligent Manufacturing University of Science and Technology BeijingBeijing100083China institute of aeronautical Power Machinery AECC Harbin Dongan Engine Co.Ltd.Harbin150000HeilongjiangChina

To achieve stable rolling,the influence of a tension mechanism of a large diameter ratio roll system on the rolling process of a strip flatness electromagnetic control rolling mill is *** the analysis of the rolling deformation zone,the deformation zone composition form of a large diameter ratio roll system and a calculation formula of neutral angle under tension are *** analyze the effect of front and post tensions on the rolling characteristic and the strip flatness control characteristic,a three-dimensional rolling finite element(FE)model of a large diameter ratio roll system with the function of roll profile electromagnetic control is established by FE software and verified by a strip flatness electromagnetic control rolling *** on the model,the strip thickness characteristic,metal transverse flow,strip flatness state,and adjustment range of the loaded roll gap are analyzed for different front and post tensions setting *** results show that changing the front or post tension setting values can improve the single-pass reduction rate of a large diameter ratio roll system and have little effect on the flatness control ability of the strip flatness electromagnetic control rolling mill.

关键词： Strip flatness electromagnetic control rolling mill Tension mechanism Roll profile electromagnetic control technology Rolling characteristic Strip flatness control characteristic

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