Analysis of the cylinder block tilting inertia moment and its effect on the performance of high-speed electro-hydrostatic actuator pumps of aircraft

Electro-hydrostatic actuator (EHA) pumps are usually characterized as high speed and small displacement. The tilting inertia moment on the cylinder block produced by the inertia forces of piston/slipper assemblies cannot be ignored when analyzing the cylinder block balance. A large tilting inertia moment will make the cylinder block tilt away from the valve plate, resulting in severe wear and significantly increased leakage. This paper presents an analytical expression for the tilting inertia moment on the cylinder block by means of vector analysis. In addition, a high-speed test rig was built up, and experiments on an EHA pump prototype were carried out at high speeds of up to 10,000 r/min. The predicted nature of the cylinder block tilt at high speeds corresponds closely to the witness marks on the dismantled EHA pump prototype. It is suggested that more attention should be given to the tilting inertia moment acting on the cylinder block of an EHA pump since both wear and leakage flow between the cylinder block and the valve plate are very much dependent on this tilting moment.     

Experimental study of an insert and its influence on churning losses in a high-speed electro-hydrostatic actuator pump of an aircraft

The speed of an Electro-Hydrostatic Actuator (EHA) pump can recently reach 20000 r/min, and its churning losses increase obviously with an increasing speed, which results in low efficiency and thus increasing heat in aircraft EHA systems. In order to reduce churning losses at high speeds, more attention should be given to the design of an insert. In this paper, the effect of an insert with different design parameters on churning losses is investigated through Computational Fluid Dynamics (CFD) simulation and experiments by calculating the difference between churning losses torques of the test pump with and without the insert based on a high-speed churning losses test rig. Analytical results show that the gap between the insert and the cylinder is critical for churning losses reduction. It is found that the churning losses of the test pump can be reduced with a decreasing gap between the cylinder block and the insert at high speeds. This is because the insert can decrease the turbulence occurrence at high speeds. The results can be used for flow field analysis and optimization of the high-speed EHA pump and provide a new method for improving efficiency of high-speed EHA pumps.     

Review of cylinder block/valve plate interface in axial piston pumps: Theoretical models,experimental investigations,and optimal design

Axial piston pumps have been widely used in aircraft hydraulic systems to supply the system with pressurized fluid. The continuous improvement of the aircraft performance has put forward the demand on aviation piston pumps for high power density, safety, and reliability. The lubricating interfaces in axial piston machines are the key design issue that greatly determines the pump performance and service life. The cylinder block/valve plate interface is one of these critical lubricating interfaces and has received considerable attention from many researchers in the last half century. This study aims to review the state‐of‐the‐art literature on the cylinder block/valve plate interface comprehensively and systematically. First, we introduce various theoretical models developed to investigate the lubrication behaviors of the interface and compare them in terms of their assumptions and limitations. Second, the experimental studies on the cylinder block/valve plate interface are presented comprehensively, where the involved test rigs are divided into three types according to their fidelity levels and measurement functionality. Third, we summarize some typical approaches of structure optimization, surface shaping, and surface strengthening, which help improve the load-carrying and anti-wear capacities of the interface under severe operating conditions. Finally, the challenges and future trends of the cylinder block/valve plate interface research are discussed briefly.     

航空燃油柱塞泵滑靴油膜的多目标优化设计

以锥形转子球面斜盘轴向燃油柱塞泵为研究对象,在分析滑靴油膜设计中的摩擦功率损失、泄漏功率损失、容积效率随滑靴的机械结构参数变化的基础上,基于遗传算法对上述多变量、多目标优化问题进行计算.权重系数法优化结果表明:优化后燃油柱塞泵设计点的摩擦功率损失和泄漏功率损失减少了7%左右,容积效率略微提升,并且优化得到的机械结构参数在不同转子转角和柱塞倾角的情况下也显示出性能上的优势,从而证明了多目标遗传算法对设计航空燃油柱塞泵油膜静压润滑是一种有效的方法.     

基于电液伺服控制燃油泵的航空发动机控制与仿真

为探索轻质化燃油系统结构,基于电调燃油变量泵的航空发动机转速控制系统,构建了柱塞泵斜盘位置电液伺服控制系统,油泵出口燃油直接输入电液伺服阀;建立了电液伺服阀线性化模型。通过数字仿真,研究了电液伺服阀工作特性,并得到了其适应性模型;在航空发动机特性半物理试验系统上,对斜盘位置电液伺服控制系统实物进行了验证试验,并与航空发动机模型一起构成了发动机转速闭环控制系统。结果表明：变输入压力的燃油电液伺服位置控制系统有效可行,变量泵工作稳定可靠,电液伺服阀模型能够准确反映实际工作状况;基于变参数PI控制算法的转速闭环控制初步取得成效。     

1 种高精度大型阶梯轴圆柱轮廓测量模型

为了提高大型阶梯轴回转部件圆柱轮廓的测量精度,提出1种考虑偏心量、工件倾斜及传感器测头偏移的3偏置测量模型。分析了综合偏置误差对阶梯轴截面圆柱轮廓残余误差的影响及偏置误差在不同工件半径下对圆柱轮廓测量结果的影响,实现了阶梯轴圆柱轮廓精度的准确评定。为了验证3偏置圆柱轮廓测量模型的有效性,采用超精密航空发动机测量仪对大直径阶梯轴的圆柱轮廓进行了测量与评定。结果表明:与传统双偏置测量模型相比,3偏置圆柱轮廓测量模型所评定的大半径阶梯轴同轴度的准确性提高了9.39μm;阶梯轴半径越大,测量精度越高。     

多层界面相陶瓷基复合材料裂纹偏转机制模拟

针对多层界面相陶瓷基复合材料(CMCs)裂纹偏转机制进行了有限元模拟。在圆柱单胞模型中,按照界面相各亚层的实际厚度建立多层界面相几何模型,然后赋予各亚层对应的组分材料参数,获取轴对称有限元模型。在此基础上,采用虚拟裂纹闭合技术(VCCT)分别计算基体裂纹在界面相处偏转与穿透两种情形的能量释放率Gd和Gp,根据断裂力学准则实现对裂纹在多层界面相内部偏转机制的分析。可以看出:各向异性界面相比各向同性界面相内部的Gd/Gp比值更大,更利于裂纹偏转的发生;总厚度相同的多层界面相与单层界面相相比,其内部的Gd/Gp比值更高,裂纹在其内部发生偏转的机会更多,且五层界面相(PyC/SiC/PyC/SiC/PyC)比三层界面相(PyC/SiC/PyC)更利于裂纹发生偏转。      

针栓喷注器中心推进剂偏转角模型分析研究

为了实现针栓喷注器中心推进剂偏转角的准确预测,基于流场分析建立了中心推进剂偏转角理论模型。从动量守恒方程推导了中心推进剂偏转角公式,通过数值仿真和试验结果对其进行验证,并分析了工况参数和结构参数对中心推进剂偏转角的影响规律。结果表明：理论模型预测值与数值仿真和试验结果很好地吻合,套筒遮挡喷注面积对偏转角影响最大,在变推力时偏转角随着套筒遮挡喷注面积增加而减小。喷注压降、中心筒壁厚和底部凹腔深度对中心偏转角影响很小,当套筒遮挡喷注面积一定时,中心筒底部有凹腔的偏转角比没有凹腔的偏转角约大6°,该模型为针栓喷注器工程设计和进一步精确计算变推力下的雾化角提供了重要参考。     

超高转速离心通风器性能仿真分析

以某型航空发动机的超高转速离心通风器为研究对象,应用欧拉-拉格朗日方法对其内部两相流场进行数值模拟.针对不同转速、入口质量流量进行了数值计算,分析其对超高转速离心通风器压降与分离效率的影响.计算表明:超高转速下,优化旋转空心轴结构可以减小离心通风器压降,提高分离效率.      

喷管面积比对推力矢量发动机特性的影响

针对矢量喷管出口面积独立无极可调控制的特点,采用数值仿真分析了偏转状态喷管面积比对矢量特性的影响机理,通过整机地面台架和高空台专项试验,获取了不同喷管面积比下推力性能、偏转推力损失、偏转效率、发动机匹配特性等数据。结果表明：非偏转状态发动机产生最大推力的喷管面积比小于气流完全膨胀对应的理论喷管面积比。发动机偏转推力损失随几何矢量角增加而增大,喷管面积比对偏转推力损失影响较小。地面台架状态相同几何矢量角下,矢量偏转效率随着喷管面积比的增大而降低,当喷管面积比达到一定值时,会出现气流分离使偏转效率进一步降低。在相同几何矢量角下,随着喷管面积比的增大,发动机节流状态转差减小,风扇工作线下移,靠近非偏转状态工作线,风扇裕度增加,工程应用中偏转状态的扩稳措施应考虑与喷管面积比的关联。     

一体化电动静液作动器(EHA)的设计与仿真分析

一体化电动静液作动系统兼备传统液压作动系统和直接驱动的机电作动系统的优点,也就是同时具备高转距和大功率密度,并且易于模块化。本文阐述了一种一体化电动静液作动器(EHA)的总体结构和工作原理,对电机、泵和液压缸的选用以及系统设计提出了明确的要求,并对其各个模块进行了建模和仿真分析。结果表明,EHA的性能能够满足现代飞机对作动系统的要求,在未来功率电传(PBW)的飞控系统中具有很好的应用前景。     

轴向柱塞泵多学科融合建模与集成优化

为了实现机液耦合条件下轴向柱塞泵的精确建模和优化设计,提出了轴向柱塞泵多学科融合建模与集成优化方法。以国产I3V2-10S型轴向柱塞泵为对象,分别建立了ADAMS机械系统模型和AMESIM液压系统模型,通过ADAMS和AMESIM之间的接口模块设计实现了柱塞泵机液耦合建模和联合仿真,并利用iSIGHT软件集成了该机液耦合模型,以该柱塞泵出口体积流量脉动率最小为目标,对配流副中吸排油节流口最大开口等效直径、吸排油闭死角、柱塞包角、吸排油预开口量等参数进行了优化设计。结果表明:在负载工况分别为10、14、18、22、26、30MPa时,优化后的泵出口流量脉动率比优化前分别降低了14.59%、18.57%、21.50%、23.44%、24.03%、25.49%,最后通过实验验证了仿真和集成优化数据的正确性。      

Coupled evolution of piston asperity and cylinder bore contour of piston/cylinder pair in axial piston pump

The wear condition of the piston/cylinder pair is crucial to the performance and reliability of the axial piston pump. The hard piston surface, the soft cylinder bore surface, and the interface oil film affects each other during the wear process. Specifically, in the mixed lubrication region, the geometry of the hard piston surface asperity directly affects the wear of soft cylinder bore surface, while the asperities may deform or even degrade when penetrating and sliding against the cylinder bore. So far, there is no suitable method to simulate their coupled evolution. This paper proposed a wear process simulation model considering the real-time interaction between the elasto-plastic deformation of the piston surface asperity, the wear contour of the cylinder bore, and the lubrication condition of the interface. An offline library of the elasto-plastic constitutive behavior of the asperity based on the finite element method (FEM) is established as a part of the simulation model to precisely analyze the deformation and degradation of the asperity and quickly invoke them in the numerical wear process simulation. The simulation and experimental results show that the piston asperity and the cylinder bore contour converge to a steady state after running-in for about 0.5 h. The distribution of the simulated asperity degradation and wear depth is also verified by the experiment.     

一种新型液压泵变排量机构的设计与仿真

为提高一体化电液作动器(EHA)的性能,对新型EHA中广泛使用的变排量液压泵中的变量机构进行了优化设计。采用锥蜗轮蜗杆传动代替了原来的齿轮传动体系并与泵壳体进行了一体化设计,采用solidworks进行了三维实体化建模,运用AMESim搭建了改进前后EHA系统的仿真模型并进行对比分析。经过仿真实验,改进后的EHA系统在整体刚度提升了31%,频率响应提升了11.2%,显著改善了系统性能,验证了设计的正确性。     

航空发动机附件机匣壳体变形分析

研究工作状态下附件机匣的壳体变形,对于提高航空发动机的安全性、可靠性具有重要意义.结合使用MASTA软件和ANSYS软件,综合考虑齿轮、轴、轴承和壳体等零部件的变形及其在传动过程中的相互影响,得到真实的轴承载荷和壳体变形结果,并提出通过计算齿轮轴平行度的方法对壳体变形量进行评估的方法.此外,采用杠杆砝码加载,模拟实际工作中扭矩传递的壳体变形试验方法.将试验值与计算值进行对比分析可知,二者虽然存在一定误差,但量级基本一致,该方法可作为机匣壳体变形试验的1种探索性测量方法.     

Analysis of the dynamic performance of an electro-hydrostatic actuator and improvement methods

As a kind of actuation mechanism for power-by-wire (PBW) actuation systems of more/all electrical aircraft, an electro-hydrostatic actuator (EHA) is a highly integrated local hydraulic actuation system. It is a volume control system consisting of a motor, a pump, an actuator, etc., which has features of high efficiency and reliability. However, the poor dynamic characteristic is one of the main factors restricting its wide application in aircraft. In this paper, the reason for the poor dynamic characteristic of an EHA is revealed from the perspectives of the natural frequency characteristic and the power requirement, respectively. In other words, the insufficiency of the motor output power at a high frequency is the main factor causing the poor dynamic characteristic of the system, and methods which include increasing the maximum output torque of the motor, reducing the rotational inertia of the motor-pump group, and adopting a double-motor-pump group configuration are proposed in this paper, by which the dynamic characteristic of the system can be improved. The feasibility of those methods are verified by simulations. Finally, the dynamic characteristic is tested on an EHA prototype, and results show that saturation of the output torque of the motor is the main factor restricting the dynamic characteristic of the EHA system.     

喷管偏转对航空发动机特性影响的试验

通过整机地面试验的方法,对喷管偏转后发动机不同工作状态下各参数的分析,获得了矢量偏转时发动机推力损失、偏转效率、发动机工作特性变化等数据.试验结果表明:在相同高压转速下,随着几何矢量角的增大,发动机的推力损失增大,偏转效率先增大后减小;在相同几何矢量角下,随着转速的增加,发动机推力损失经历由增大到减小的过程,矢量喷管的偏转效率增大,但偏转效率均小于1;节流状态时发动机转速差随着几何矢量角的增大而增大,中间状态时发动机转速差不受几何矢量角的影响;发动机节流状态时的矢量偏转使风扇工作线上移,风扇裕度减小,工程应用中需考虑扩稳措施.      

Design and Simulation of Electro-hydrostatic Actuator with a Built-in Power Regulator

The electro-hydrostatic actuator (EHA) is a kind of power-by-wire (PBW) actuator that converts the electrical power into localized hydraulic power for flight control. By removing the central hydraulic power supply together with hydraulic pipes, an EHA's reliability and efficiency are greatly improved but its frequency width and stiffness decreased. To overcome the drawback, this article proposes a novel structure of EHA associated with a power regulator. Composed of a high-pressure accumulator and a proportional valve, it can store and harness the hydraulic power flexibly according to the changing control requirements. The concept of transferred volume is put forward to estimate the capability of the power regulator. The actuator output position can be kept fixed with a hydraulic lock. The compounded control is specially developed to ensure the actuator system to operate in a correct manner. The simulation results indicate that the new-brand actuator results in efficient expanding of the system frequency width with an optimal power supply.     

Modeling and control of a novel electro-hydrostatic actuator with adaptive pump displacement

The variable pump displacement and variable motor speed electro-hydrostatic actuator (EHA), one of the three types of EHAs, has advantages such as short response time, flexible speed regulation, and high efficiency. However, the nonlinearity of its double-input single-output system poses a great challenge for system control. This study proposes a novel EHA with adaptive pump displacement and variable motor speed (EHA-APVM). A closed-loop position is realized using a servomotor. Moreover, the displacement varies with the system pressure; thus, the EHA-APVM is a single-input and single-output system. Firstly, the working principles of the EHA-APVM and the pump used in the system are introduced. Secondly, a nonlinear mathematical model of the proposed EHA-APVM control system is established, and a feedback back-stepping (FBBS) control algorithm is introduced to transform the complex nonlinear system into a linear system on the basis of the back-stepping control theory. Finally, simulation results prove that the EHA-APVM has a quick response and high robustness to variations of the load and the pump displacement. In this work, the size and weight of the motor are significantly reduced because the maximum power requirement is reduced, which is very beneficial for using the actuator in airborne equipment.     

Study of RCS characteristics of tilt-rotor aircraft based on dynamic calculation approach

To study the Radar Cross-Section(RCS) characteristics of the tilt-rotor aircraft, a dynamic calculation approach that takes into account rotor rotation and nacelle tilt is presented.Physical optics and physical theory of diffraction are used to deal with the instantaneous electromagnetic scattering of the target. The RCS of the aircraft in the helicopter mode, fixed-wing mode and transition mode is analyzed. The results show that in the fixed-wing mode, the blade has a weaker deflection effect o...