Research on Automatic Test System of Engine Blade Natural Frequency

Blades are one of the important components on aircraft engines.If they break due to vibration failure,the normal operation of the entire engine will be offected.Therefore,it is necessary to measure their natural frequency before installing them on the engine to avoid resonance.At present,most blade vibration testing systems require manual operation by operators,which has high requirements for operators and the testing process is also very cumbersome.Therefore,the testing efficiency is low and cannot meet the needs of efficient testing.To solve the current problems of low testing efficiency and high operational requirements,a high-precision and high-efficiency automatic test system is designed.The testing accuracy of this system can reach ±1%,and the testing efficiency is improved by 37% compared to manual testing.Firstly,the influence of compression force and vibration exciter position on natural frequency test is analyzed by amplitude-frequency curve,so as to calibrate servo cylinder and fourdimensional motion platform.Secondly,the sine wave signal is used as the excitation to sweep the blade linearly,and the natural frequency is determined by the amplitude peak in the frequency domain.Finally,the accuracy experiment and efficiency experiment are carried out on the developed test system,whose results verify its high efficiency and high precision.

Parametric Modeling System for Cooling Turbine Blade Based on Feature Design

Based on feature modeling and mathematical analysis methods,a process-oriented and modular parametric design system for advanced turbine cooling blade is developed with UG API,aiming at the structural complexity and high design difficulty of aero-engine cooling turbine blade.The relationship between the external and internal body features,the body attached feature is analyzed as viewed from the feature and parameter terms.The parametric design processes and design examples of the external body shape,tenon,platform and internal body shape,ribs,pin fins are introduced.The system improves the design efficiency of cooling turbine blade and establishes the foundation of multidisciplinary design optimization procedure for it.

An integration system for investment casting mould design of aeroengine turbine blade

An integration system was developed to satisfy the need of information integration in the process of designing, investment casting and monitoring aero-engine's turbo blade. The general architecture is detailed presented in this paper. The system mainly comprises of product master model, design information management, anti-deformation design of mould cavity, intelligence mould design and blade testing. The developed system can manage mould design and blade test data flow, optimize mould design process and achieve the goal of integration design.

Modeling and Dynamic Analysis for the Foundation of a Blade-Rotor System

In order to achieve the model-based fault monitoring and diagnosis,an accurate model for the rotor system is necessary to locate and quantify faults.Since the dynamic characteristics of a blade-rotor system is influenced by foundation flexibility,the modeling and dynamic analyses on the foundation were sequentially investigated.Firstly,the effect of element size on the model convergence was investigated using the forward difference quotient as the slope of the frequency difference,which found that the model converged when the element size refined to 4mm.Secondly,a modal analysis and a harmonic response analysis were performed to obtain the dynamic characteristics of the foundation structure.Finally,an optimization to the foundation utilizing an additional stiffener was conducted to reduce the foundation response and make the critical speed far away from the working frequency band of 20—50Hz.

Mechanism of internal thermal runaway propagation in blade batteries

Blade batteries are extensively used in electric vehicles,but unavoidable thermal runaway is an inherent threat to their safe use.This study experimentally investigated the mechanism underlying thermal runaway propagation within a blade battery by using a nail to trigger thermal runaway and thermocouples to track its propagation inside a cell.The results showed that the internal thermal runaway could propagate for up to 272 s,which is comparable to that of a traditional battery module.The velocity of the thermal runaway propagation fluctuated between 1 and 8 mm s^(-1),depending on both the electrolyte content and high-temperature gas diffusion.In the early stages of thermal runaway,the electrolyte participated in the reaction,which intensified the thermal runaway and accelerated its propagation.As the battery temperature increased,the electrolyte evaporated,which attenuated the acceleration effect.Gas diffusion affected thermal runaway propagation through both heat transfer and mass transfer.The experimental results indicated that gas diffusion accelerated the velocity of thermal runaway propagation by 36.84%.We used a 1D mathematical model and confirmed that convective heat transfer induced by gas diffusion increased the velocity of thermal runaway propagation by 5.46%-17.06%.Finally,the temperature rate curve was analyzed,and a three-stage mechanism for internal thermal runaway propagation was proposed.In Stage I,convective heat transfer from electrolyte evaporation locally increased the temperature to 100℃.In Stage II,solid heat transfer locally increases the temperature to trigger thermal runaway.In StageⅢ,thermal runaway sharply increases the local temperature.The proposed mechanism sheds light on the internal thermal runaway propagation of blade batteries and offers valuable insights into safety considerations for future design.

Blade-Loss-Caused Rubbing Dynamic Characteristics of Rotor-Bladed Disk-Casing System

Considering the elastic supports,the finite element model of rotor-bladed disk-casing system is established using commercial software ANSYS/LS-DYNA.Assuming that broken blade is released from the disk,the complicate rubbing responses of unbalanced rotor-bladed disk-casing system are studied under different operational speeds.In addition,influences of both plastic deformation of blade and casing failure are analyzed.The results show that there exist some multiple even fractional frequencies in the transient and steady vibration responses of unbalanced rotor.Besides,one nodal diameter vibration of bladed disk coupling with the lateral vibration of the shaft as well as the first order bending vibration of blade can be excited under low operational speed,while the first order bending vibration of blade coupling with the lateral vibration of disk-shaft is easily excited under high operational speed.During rubbing process,three distinct contact states can be observed:broken blade-casing contact,broken blade-blade component-casing contact and broken blade-casing contact/blade component-casing contact/blade selfcontact.It is worth noting that the third contact state is related to the operational speed.With the increase of operational speed,self-contact in the blade may occur.

Study of the helicopter blade running elevation measurement system

Helicopter blade running elevation measurement is an important measure target in helicopter blade dynamic balance experimentation. The elevation influences the helicopter＇ s security and other performance capabilities. In testing, however, it has been difficult to measure the elevation when the rotor reaches high speeds. To get a simple, fast and highly accurate measurement system, photo electricity technology was applied to measuring the blade running elevation. Discussed is the measurement principle of blade running elevation, tire design of the measurement system and analysis of the measurement precision.

An Advanced Control Strategy for Dual-Actuator Driving System in Full-Scale Fatigue Test of Wind Turbine Blades

A new dual-actuator fatigue loading system of wind turbine blades was designed.Compared with the traditional pendulum loading mode,the masses in this system only moved linearly along the loading direction to increase the exciting force.However,the two actuators and the blade constituted a complicated non-linear energy transferring system,which led to the non-synchronization of actuators.On-site test results showed that the virtual spindle synchronous strategy commonly used in synchronous control was undesirable and caused the instability of the blade’s amplitude eventually.A cross-coupled control strategy based on the active disturbance rejection algorithm was proposed.Firstly,a control system model was built according to the synchronization error and tracking error.Furthermore,based on arranging the transition process,estimating the system state and error feedback,and compensating disturbance,an active disturbance rejection controller was designed by adopting the optimal control function.Finally,on-site test results showed that the cross-coupled control strategy based on the active disturbance rejection algorithm could ensure the synchronization of two actuators.The maximum speed synchronization error of the two motors was less than 16 RPM,the displacement synchronization error of the two actuators was less than 0.25 mm and approaching zero after 4 seconds,and the peak value of vibration of the blade was less than 5 mm,which satisfied the fatigue test requirement.

An Automated Ultrasonic NDT System for In-Situ Inspection of Wind Turbine Blades

It is crucial to maintain wind turbine blades regularly, due to the high stress leading to defects or damage. Conventional methods require shipping the blades to a workshop for off-site inspection, which is extremely time-consuming and very costly. This work investigates the use of pulse-echo ultrasound to detect internal damages in wind turbine blades without the necessity to ship the blades off-site. A prototype 2D ultrasonic NDT （non-destructive testing） system has been developed and optimised for in-situ wind turbine blade inspection. The system is designed to be light weight so it can be easily carried by an inspector onto the wind turbine blade for in-situ inspection. It can be operated in 1D A-scan, 2D C-scan or 3D volume scan. A software system has been developed to control the automated scanning and show the damage areas in a 2D/3D map with different colours so that the inspector can easily identify the defective areas. Experiments on GFRP （glass fibre reinforced plastics） and wind turbine blades （made of GFRP） samples showed that internal defects can be detected. The main advantages of this system are fully automated 2D spatial scanning and the ability to alert the user to the damage of the inspected sample. It is intended to be used for in-situ inspection to save maintenance time and hence considered to be economically beneficial for the wind energy industry.

The Third-Order Viscoelastic Acoustic Model Enables an Ice-Detection System for a Smart Deicing of Wind-Turbine Blade Shells

The present work is based on the third-order partial differential equation (PDE) of acoustics of viscoelastic solids for the quasi-equilibrium (QE) component of the average normal stress. This PDE includes the stress-relaxation time (SRT) for the material and is applicable at any value of the SRT. The notion of a smart deicing system (SDS) for blade shells (BSs) of a wind turbine is specified. The work considers the stress in a BS as the one caused by the operational load on the BS. The work develops key design issues of a prospective ice-detection system (IDS) able to supply an array of the heating elements of an SDS with the element-individual spatiotemporal data and procedures for identification of the material parameters of atmospheric-ice (AI) layer accreted on the outer surfaces of the BSs. Both the SDS and IDS flexibly allow for complex, curvilinear and space-time-varying shapes of BSs. The proposed IDS presumes monitoring of the QE components of the normal stresses in BSs. The IDS is supposed to include an array of pressure-sensing resistors, also known as force-sensing resistors (FSRs), and communication hardware, as well as the parameter-identification software package (PISP), which provides the identification on the basis of the aforementioned PDE and the data measured by the FSRs. The IDS does not have hardware components located outside the outer surfaces of, or implanted in, BSs. The FSR array and communication hardware are reliable, and both cost- and energy-efficient. The present work extends methods of structural-health/operational-load monitoring (SH/OL-M) with measurements of the operational-load-caused stress in closed solid shells and, if the prospective PISP is used, endows the methods with identification of material parameters of the shells. The identification algorithms that can underlie the PISP are computationally efficient and suitable for implementation in the real-time mode. The identification model and algorithms can deal with not only the single-layer systems such as the BS layer without the AI layer or two-layer systems but also multi-layer systems. The outcomes can be applied to not only BSs of wind turbines but also non-QE closed single- or multi-layer deformable solid shells of various engineering systems (e.g., the shells of driver or passenger compartments of ships, cars, busses, airplanes, and other vehicles). The proposed monitoring of the normal-stress QE component in the mentioned shells extends the methods of SH/OL-M. The topic for the nearest research is a better adjustment of the settings for the FSR-based measurement of the mentioned components and a calibration of the parameter-identification model and algorithms, as well as the resulting improvement of the PISP.

A Compact Laser Shearography System for On-Site Robotic Inspection of Wind Turbine Blades

Shearography is an optical technique in the field of nondestructive evaluation(NDE)of various materials.Its main advantages are that it is noncontact type and can cover a large area in a single inspection.As a result,although it has been widely acknowledged as an effective technique particularly for NDE of composite materials to detect subsurface defects such as delamination,disbond,cracks,and impact damages,the use of shearography for on-site inspection of wind turbine blades(WTBs)has not been reported.This is due to wind causing structural vibration in the WTB.The solution in this paper is to make the shearography sit on the WTB during inspection when the WTB is parked,so that the relative motion between the shearography and the WTB is minimized within the tolerance of the shearography system.The ultimate goal of the solution is to enable a robot-assisted shearography system to inspect the WTB on-site.This paper presents the research work on a new shearography design for integration with a robotic climber for on-site WTB inspection.The approach is tested and evaluated in experimental settings,and a comparative assessment of the approach with other robotic NDE techniques is carried out.The results demonstrate the potential benefits and suitability of the approach for on-site robotic inspection of WTBs.

Numerical simulation on directional solidification and heat treatment processes of turbine blades

Study on turbine blades is crucial due to their critical role in ensuring the efficient and reliable operation of aircraft engines.Nickel-based single crystal superalloys are extensively used in the hot manufacturing of turbine blades due to their exceptional high-temperature mechanical properties.The hot manufacturing of single crystal blades involves directional solidification and heat treatment.Experimental manufacturing of these blades is time-consuming,capital-intensive,and often insufficient to meet industrial demands.Numerical simulation techniques have gained widespread acceptance in blade manufacturing research due to their low energy consumption,high efficiency,and rapid turnaround time.This article introduces the modeling and simulation of hot manufacturing in single crystal blades.The discussion outlines the prevalent mathematical models employed in numerical simulations related to blade hot manufacturing.It encapsulates the advancements in research concerning macro to micro-level numerical simulation techniques for directional solidification and heat treatment processes.Furthermore,potential future trajectories for the numerical simulation of single crystal blade hot manufacturing are also discussed.

Optimized Design of Bio-Inspired Wind Turbine Blades

To enhance the aerodynamic performance of wind turbine blades,this study proposes the adoption of a bionic airfoil inspired by the aerodynamic shape of an eagle.Based on the blade element theory,a non-uniform extraction method of blade elements is employed for the optimization design of the considered wind turbine blades.Moreover,Computational Fluid Dynamics(CFD)is used to determine the aerodynamic performances of the eagle airfoil and a NACA2412 airfoil,thereby demonstrating the superior aerodynamic performance of the former.Finally,a mathematical model for optimizing the design of wind turbine blades is introduced and a comparative analysis is conducted with respect to the aerodynamic performances of blades designed using a uniform extraction approach.It is found that the blades designed using non-uniform extraction exhibit better aerodynamic performance.

Blade Wrap Angle Impact on Centrifugal Pump Performance:Entropy Generation and Fluid-Structure Interaction Analysis

The centrifugal pump is a prevalent power equipment widely used in different engineering patterns,and the impeller blade wrap angle significantly impacts its performance.A numerical investigation was conducted to analyze the influence of the blade wrap angle on flow characteristics and energy distribution of a centrifugal pump evaluated as a low specific speed with a value of 69.This study investigates six impellermodels that possess varying blade wrap angles(95°,105°,115°,125°,135°,and 145°)that were created while maintaining the same volute and other geometrical characteristics.The investigation of energy loss was conducted to evaluate the values of total and entropy generation rates(TEG,EGR).The fluid-structure interaction was considered numerically using the software tools ANSYS Fluent and ANSYSWorkbench.The elastic structural dynamic equation was used to estimate the structural response,while the shear stress transport k–ωturbulence model was utilized for the fluid domain modeling.The findings suggest that the blade wrap angle has a significant influence on the efficiency of the pump.The impeller featuring a blade wrap angle of 145°exhibits higher efficiency,with a notable increase of 3.76%relative to the original model.Variations in the blade wrap angle impact the energy loss,shaft power,and pump head.The model with a 145°angle exhibited a maximum equivalent stress of 14.8MPa and a total deformation of 0.084 mm.The results provide valuable insights into the intricate flow mechanism of the centrifugal pump,particularly when considering various blade wrap angles.

Influence of Blade Number on the Performance of Hydraulic Turbines in the Transition Stage

To analyze the effect of blade number on the performance of hydraulic turbines during the transient stage in which theflow rate is not constant,six hydraulic turbines with different blade numbers are considered.The instantaneous hydraulic performance of the turbine and the pressure pulsation acting on the impeller are investigated numerically by using the ANSYS CFX software.The ensuing results are compared with the outcomes of experimental tests.It is shown that thefluctuation range of the pressure coefficient increases with time,but the corresponding range for the transient hydraulic efficiency decreases gradually when theflow velocity transits to larger values.During the transition to smallflow velocity,thefluctuation range of the pressure coefficient gradually decreases as time passes,but the correspondingfluctuation range of its transient hydraulic efficiency gradually becomes larger.Thefluctuation range in the Z9 case is small during the transition.The main frequency of transient hydraulic efficiency pulsation is equal to the blade frequency.At the main frequency,Z7 has the largest amplitude of the hydraulic efficiency pulsation,Z10 has the smallest amplitude,and the difference between Z7 and Z9 is limited.As the number of blades grows,the pressure pulsation during the transition process gradually decreases,but the pressure pulsation of Z10 at the volute tongue is larger.In the steady state,Z9 has the highest efficiency and in the transient stage,the pressure coefficientfluctuation range is small.Accordingly,for the hydraulic turbine Z9,the performance is optimal.

Surface Construction System of the Airfoil Blade Based on B-spline

According to the construction principle of B-spline, a formula of surface construction for airfoil blade with the given points has been derived. Meanwhile, the surface construction system for airfoil blade in practice as well as menus for the system have been constructed with the help of the commercial software (AutoCAD R14). The result in this paper is helpful for CAD/CAM of airfoil blades.

Research on the Icing Diagnosis ofWind Turbine Blades Based on FS–XGBoost–EWMA

In winter,wind turbines are susceptible to blade icing,which results in a series of energy losses and safe operation problems.Therefore,blade icing detection has become a top priority.Conventional methods primarily rely on sensor monitoring,which is expensive and has limited applications.Data-driven blade icing detection methods have become feasible with the development of artificial intelligence.However,the data-driven method is plagued by limited training samples and icing samples;therefore,this paper proposes an icing warning strategy based on the combination of feature selection(FS),eXtreme Gradient Boosting(XGBoost)algorithm,and exponentially weighted moving average(EWMA)analysis.In the training phase,FS is performed using correlation analysis to eliminate redundant features,and the XGBoost algorithm is applied to learn the hidden effective information in supervisory control and data acquisition analysis(SCADA)data to build a normal behavior model.In the online monitoring phase,an EWMA analysis is introduced to monitor the abnormal changes in features.A blade icing warning is issued when themonitored features continuously exceed the control limit,and the ambient temperature is below 0℃.This study uses data fromthree icing-affected wind turbines and one normally operating wind turbine for validation.The experimental results reveal that the strategy can promptly predict the icing trend among wind turbines and stably monitor the normally operating wind turbines.

Assessment of Similitude Behavior in Natural Frequencies of Printed Turbine Blade

Improving structures involves comparing old and new designs on a key parameter.Calculating the percent change in performance is a method to assess.This paper proposes a cost-effective analogy by generating replicas of additive manufactured aluminum alloy(Al Si10Mg)body-centered cubic lattice(BCC)based turbine blade(T106C)with the same in poly-lactic acid(PLA)material and their comparison in the context of percent change for natural frequencies.Initially,a cavity is created inside the turbine blade(hollow blade).Natural frequencies are obtained experimentally and numerically by incorporating BCC at 50%and 80%of the cavity length into the hollow blade for both materials.The cost of manufacturing the metal blades is 90%more than that of the PLA blades.The two material blade designs show a similar percentage variation,as the first-order mode enhancs more than 5%and the second-order mode more than 4%.To observe the behavior in another material,both blades are analyzed numerically with a nickel-based U-500 material,and the same result is achieved,describing that percent change between designs can be verified using the PLA material.

Data-Driven Modeling for Wind Turbine Blade Loads Based on Deep Neural Network

Blades are essential components of wind turbines.Reducing their fatigue loads during operation helps to extend their lifespan,but it is difficult to quickly and accurately calculate the fatigue loads of blades.To solve this problem,this paper innovatively designs a data-driven blade load modeling method based on a deep learning framework through mechanism analysis,feature selection,and model construction.In the mechanism analysis part,the generation mechanism of blade loads and the load theoretical calculationmethod based on material damage theory are analyzed,and four measurable operating state parameters related to blade loads are screened;in the feature extraction part,15 characteristic indicators of each screened parameter are extracted in the time and frequency domain,and feature selection is completed through correlation analysis with blade loads to determine the input parameters of data-driven modeling;in the model construction part,a deep neural network based on feedforward and feedback propagation is designed to construct the nonlinear coupling relationship between the unit operating parameter characteristics and blade loads.The results show that the proposed method mines the wind turbine operating state characteristics highly correlated with the blade load,such as the standard deviation of wind speed.The model built using these characteristics has reasonable calculation and fitting capabilities for the blade load and shows a better fitting level for untrained out-of-sample data than the traditional scheme.Based on the mean absolute percentage error calculation,the modeling accuracy of the two blade loads can reach more than 90%and 80%,respectively,providing a good foundation for the subsequent optimization control to suppress the blade load.

Effect of Rigid Pitch Motion on Flexible Vibration Characteristics of a Wind Turbine Blade

Adynamic pitch strategy is usually adopted to improve the aerodynamic performance of the blade of awind turbine.The dynamic pitch motion will affect the linear vibration characteristics of the blade.However,these influences have not been studied in previous research.In this paper,the influences of the rigid pitch motion on the linear vibration characteristics of a wind turbine blade are studied.The blade is described as a rotating cantilever beam with an inherent coupled rigid-flexible vibration,where the rigid pitch motion introduces a parametrically excited vibration to the beam.Partial differential equations governing the nonlinear coupled pitch-bend vibration are proposed using the generalized Hamiltonian principle.Natural vibration characteristics of the inherent coupled rigid-flexible system are analyzed based on the combination of the assumed modes method and the multi-scales method.Effects of static pitch angle,rotating speed,and characteristics of harmonic pitch motion on flexible natural frequencies andmode shapes are discussed.It shows that the pitch amplitude has a dramatic influence on the natural frequencies of the blade,while the effects of pitch frequency and pith phase on natural frequencies are little.