anecom aerotest

AneCom AeroTest Engineering and Test Services

for the Aero Engine and Gas Turbine Industry

Challenges of Trend Monitoring on Modular Test Setups (M. Werther, M.O. Draeger, F. Grewe)

InnoTesting 2014 – “Future Technologies and Processes for Simulation and Testing”

February 20 – 21, 2014

© AneCom AeroTest 2014

Innotesting 2014 Slide 2

Content

Background Information

Trend Monitoring for Drivelines

UFFA Trend Monitor

Summary



Content



UFFA Trend Monitor

Summary



Company

Certified to EN 9100 and EN 14001

Founded 2002

Business Engineering and Testing Services for the Aero Engine and Gas Turbine Industry



• 41 customers from aviation and industrial

gas turbine industry

• More than 890 projects in 11 years

Customer Project History

„ ... Extremely high professionality profused by each member of the operative personnel involved in the test setup and execution. Excellent program management performed by the project manager... “

Customer statement

Quality. Flexibility. Solution Orientation. …… and Satisfied Customers worldwide.



Aspects of trend monitoring

• trend analysis - the attempt to see the future

• information base: real data in relation to time

• main reasons for trend analysis regarding maintenance :

scheduling maintenance

reduce downtimes

safety in operation

efficiency maintenance

short: maintenance if necessary but in time

reducing costs

• Main problems:

- sufficient data base

- consideration of boundary conditions

- unknown disturbances

Maintenance

TREND

Run

http://esol.britishcouncil.org/professional-podcasts/trend-analysis



Project History & Testbed Reliability

• 11 customers from aviation and industrial gas turbine industry:

68 test campaigns in 11 years

> 4000 test running hours accumulated in total

• Since start of operation in 2003 no impact on customer

programs on order due to facility downtime

Test facility readiness level 2012/13: > 98%



2 Compressor Test Facilities

for aero-performance testing

Drive power 18MW (24000hp)

Air flow up to 200kg/s

Split flow capability for fan testing

Min. inlet pressure 20kPa (0,2bar)

Exhaust temperature up to 650oC

Operation of Compressor Test Centre Wildau



Fan Noise Test Facility

for aero-performance testing and noise investigations

under free-field conditions

• Drive power 18MW (24000 hp)

• Air flow up to 200kg/s

• Split flow capability for fan testing

• 1000m2 anechoic chamber (200Hz – 40kHz)

• Far field microphone array

Operation of Compressor Test Centre Wildau



Modular Concept to improve Test Efficiency

• Universal test vehicle for fan noise testing, adaptable to customer requirements

• Variation of aerodynamic and acoustic configuration also in the bypass duct

– Positioning of OGV and ESS

– Variation of bypass duct geometry

– Use of hard walled and acoustic liners

– Engine specific installations (bifurcations, bleed ports, etc.)

• Comprehensive instrumentation capability

for aerodynamic and noise measurements

• Major configuration changes on the bench



Content



UFFA Trend Monitor

Summary



Trend monitoring for motor drivelines

• Driveline is composed of the motor, gearbox, torquemeter and shaft

• Oil supply system for all bearings

• Plenty of parameters available (minimum of 100 per driveline)

A simplified assembly valid to all ACAT drivelines Oil supply system

Gear set



• Driveline is composed of the motor, gearbox, torquemeter and shaft

• Oil supply system for all bearings

• Plenty of parameters available (minimum of 100 per driveline)


A simplified assembly valid to all ACAT drivelines Oil supply system




• To achieve comparability Zero torque datum events (no compressor installed)

Draw a distinction between testbed & driveline parameters

Building parameter groups

• To achieve multiplexed information Determine significant parameters

Accomplish database reduction

Keep important system information

• Parameter groups segmentation

Speeds

Vibrations

Temperatures

Torques

Flow rate (oil supply and cooling system)

Parameters

Algorithms

System characteristics

Trend data of an event

Trend monitoring Visualization



• Execution Develop algorithms (physical characteristics, statistic methods) Visualization (concise)


ZTD log read Data analysis Visual data

Extract for TDM

TDM log read Data analysis

Visual trend data Extract the TDM

ZTD

Eva

luation

TD

M E

valu

ation

DATA Archiv

Evaluated ZTD log

TDM log

Trend analysis file



Content



UFFA Trend Monitor

Summary



NON VARIABLE

PARTS

VARIABLE PARTS

(CUSTOMER SPECIFIC

HARDWARE)

Challenges in UFFA Trend Monitoring



• Huge data sets (about 500GB / test day)

• Generated data are sensitive (customers possession)

• No consistent operating run program

Challenges in UFFA Trend Monitoring

NON

VARIABLE

PARTS

VARIABLE PARTS

(CUSTOMER

SPECIFIC

HARDWARE)



Approach to implement the UFFA Trend Monitor

• Provide background information for the engineer

• Filter parameters independent from UFFA configuration

• Separation of customers data by

Excluding parameters non-related to machine condition

Using AneCom intern designations

• Further Requirements:

Link several test sets into one (unsteady operating run over speed intervals)

Transform, reduce and compress raw data

Automatic program run

NON

VARIABLE

PARTS

VARIABLE PARTS

(CUSTOMER

SPECIFIC

HARDWARE)



Execution of UFFA Trend Monitor

• Classified parameter list (about 30 remaining)

• Analysis concept:

Vibration signals to perform engine order and bearing analysis by using FFT

Temperatures statistic indicators

Displacement statistic indicators

Pressures (in progress)

Chip detector (quantification)

• Precise overview of analyzed information in a graphical user interface



UFFA Trend Monitor program structure

Data

dynamic measurements – raw data & config file slow-rate measurements – raw data Chip detector – laboratory test results boundary conditions UFFA configuration information

Analysis

Visualization Evaluation of test data

Save record Basic file for trend monitoring Trend monitor file Trend monitor file

Trend monitor file

Trend monitoring

Processing



Content



UFFA Trend Monitor

Summary



What has been achieved so far

• Extracting important information from test data sets

• Safety of customers data

• Visualization of data in a graphical user interface

Assemble multiple test runs in a chart

Conclusions by engineer regarding next maintenance events are possible



Outlook in trend monitoring

• Optimization of both programs

Improve user-friendliness

• Enhancement of automation

• Interpretation of life cycles by the program

• In case of UFFA: Life cycle monitoring of structure parts that are used frequently for instance standard ESS & OGV

• Implementation of bearing and oil pressure analysis

• Further development and derivations to limits out of existing data base

Limits and criteria independent from UFFA configuration

• Determination of trends (no extrapolation)



Further Discussions



Contact

AneCom AeroTest GmbH

im Zentrum für Luft- und Raumfahrt

Freiheitstrasse 122, 15745 Wildau, Germany

www.anecom.de

Ansprechpartner

Marek Werther

Group Leader Measurement

Telefon +49 (0) 3375 92 26 73

Mail: [email protected]



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