Engine Testing

14.00-14.30 Modernization of a measurement command and control system on a rocket engine test bed for the Ariane 5 main engine

Carsten Stein, Manager Sales & Business Consulting, Werum Software & Systems AG

At its facilities in Lampoldshausen DLR operates several test beds for rocket engines. One of the facilities built in the late 80’s is for the Ariane 5 main engine. The main command and control system also originates from the 80s and it has become more and more difficult to maintain the operational status over the years since spare parts have become obsolete and the system is not built any more. So the decision was made to replace the measurement, command and control (MCC) system by a new state of the art system. The development of the MCC system was performed by three companies (Werum Software & Systems AG (Lueneburg), S.E.A. Datentechnik GmbH (Cologne) and Cegelec (Wavre, Belgium) with Werum being the prime contractor. The system was successfully integrated and accepted in 2009. In the meantime the system has proven its capabilities and performance during the latest ARTA campaign with a Vulcain 2 engine. Within the presentation it will be shown how the specific requirements with regards to test bed safety and data integrity have been approached. An important point was for the customer, that always data loss has to be prevented and that control of the bench is always possible with the aim of safely shutting down the engine. It will be discussed what other issues besides technical considerations have to be taken into account in order to migrate an existing test bed with all its proven procedures and success stories to a new system.

14.30-15.00 Accelerated Jet engine design process through model-based testing and test-based modeling

Jan Debille, Aerospace Testing Solutions Manager, LMS

Virtual engine and whole engine model development projects aim at enhanced integration of test and CAE in the design of jet engines. CAE data is used to define the test strategy and planning. Once actual tests on components, sub-assemblies or whole engines are preformed, data is interpreted and compared to CAE predictions. Subsequently, FE models are updated using the test results. This process leads to a more reliable model to be used in current development programs and future designs. It also allows for better modeling capability. This presentation gives practical examples of structural dynamics modeling of engine components.

15.00-15.30 Diagnostics of aircraft engine spark plugs and ignition systems

Dmitry Golentsov, head of sector, CIAM

The knowledge and the control of spark discharge parameters is important problem. It is necessary during manufacturing, tests and operation of ignition systems of aircraft engines for monitoring of the operation condition of spark plugs, for rational choice of parameters of ignition systems to provide the reliable start of combustion chambers. There is both the method and the diagnostic equipment for measurement of primary parameters of spark discharge (the values both of discharge current and voltage) and calculation on their basis of the discharged energy and the other ignition system parameters.

15.30-16.00 ROTRANS: High performance Rotary Transmitters 0-42'000 rpm and more

Jean-Luc Mouret, General Manager, Jordil-Technic Rotary-Transmitters

ROTRANS – 42'000 rpm, High Performance Rotary Transmitters. ROTRANS is a continuous analogue one-to-one signal transmitter. ROTRANS uses unique metal liquid technology which enables this high quality of transmission, this permits the discovery of unknown phenomena and is easy to use and reliable just like a cable. ROTRANS rotate from 0 to 42'000 rpm, and a special version up to 70'000 rpm. The ROTRANS durability is one of its many appreciated. Ideal by blade vibration measurement and resonance frequencies analyses of turbine, only with strain gauges. A high dynamic measurement of torque can only be realised using strain-gauges and ROTRANS, without pre-amplification or supplementary electronics. The quality of the signal transmission is such that any vibration can be measured with strain-gauges and ROTRANS. Why not to contact us for your next application ?

WEDNESDAY 19 MAY 2010 - DAY 2

Auditorium 1 - Day 2

Data Acquisition & Sensor Technology

10.00-10.30 How to manage and optimise sensors’ channel connection to the Data Acquisition System on test campaigns involving thousands of sensors?

David Croenne, CTO, Global Vision Systems

This presentation is based on Airbus A380 structural static test campaign case study. Within a test campaign composed of dozens of tests, thousands of sensors are used and reused during their life-time. This requires connections configuration plan that need to be set quickly and optimized in real-time. It is not possible to predict if a sensor will be out of order soon, but it is possible to greatly improve swapping connection operations by: - gathering into one database all the tests sensors configuration plan - knowing the actual state of each sensor’s channel : in order, requiring maintenance, connected, disconnected - knowing the actual position of the sensor and its cable’s position as the position of the Data Acquisition System’s hubs and cards. It is then possible to take all these information into consideration to: - optimise sensor’s channels connections swapping to the Data Acquisition System - prevent inconsistent swapping commands by taking into account the geographical position of the hubs, cards and channel’s cable’s end - optimise the test campaign schedule by swapping tests and checking in real-time the consequences in term of test preparation efforts (number of sensors’ channels to connect, to disconnect and to repair).

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