1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2012 SAE International All rights reserved. No part of this p
3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AIR5509 AEROSPACE INFORMATION REPORT AIR5509 Issued 2012-11 Using Engine Test Dat
5、a to Model Engine Performance RATIONALE An accurate engine system model is required to support engine and aircraft system development. This SAE Aerospace Information Report (AIR) documents the process of matching an engine cycle model to test data and identifies common terminology to facilitate comm
6、unication among all interested parties. TABLE OF CONTENTS 1. SCOPE 2 1.1 Purpose . 2 1.2 Overview . 2 2. REFERENCES 2 2.1 Applicable Documents 2 2.1.1 SAE Publications . 3 2.2 Definitions . 3 3. FUNCTIONALITY 4 3.1 Instrumentation Verification (Engine not running) 4 3.2 Raw Data Acquisition 4 3.3 Ra
7、w Data Verification (Engine Running) 5 3.4 Engineering Units (EU) Data Conversion . 5 3.5 Engineering Units Data Verification 5 3.6 Engineering Units Data Reduction 5 3.7 Data Analysis 5 3.7.1 Verify Reduced Data . 5 3.7.2 Develop Component Adjustments 5 3.7.3 Develop Adjustments to Overall Performa
8、nce 6 3.7.4 Develop Engine Data Match . 6 3.7.5 Refer Reduced Data to Reference Conditions . 6 3.8 Document Results . 6 4. EXAMPLES . 6 4.1 Ground Test Data Reduction and Model Interaction 7 4.2 Altitude Test Facility Data Reduction and Model Interaction 8 5. NOTES 9 SAE AIR5509 Page 2 of 9 1. SCOPE
9、 This document defines the process steps involved in collecting and processing engine test data for use in understanding engine behavior. It describes the use of an aero-thermal cycle model for reduction and analysis of those data. The analysis process may include the calculation of modifiers to mat
10、ch the model to measured data, and prediction of engine performance based on that analysis 1.1 Purpose The purpose of this AIR is to define common terminology for the processes used to collect and analyze engine test data. 1.2 Overview In order to meet engine system and aircraft related requirements
11、 gas turbine engines must demonstrate certain capabilities such as: predefined thrust, shaft torque, or power non-exceedance of prescribed mechanical limits within the operating envelope fuel efficiency level performance in various configurations Validation of these capabilities typically employs sp
12、ecialized engine performance models that may be adjusted to match test data and then used to verify conformance. In order to reproduce the test data, the engine performance program will typically modify internal component representations by applying scalars and adders to adjust efficiencies and flow
13、 capacities from nominal design values. The significant advantage of these programs is that thermodynamically correct methods are employed and are thus valid over a much greater range than without adders and scalars. Numerous test data points are needed to fully characterize engine operation over th
14、e full flight envelope. Once the engine model is matched to steady-state data, it may be necessary to characterize transient engine operation. Therefore, additional dynamic effects may be applied to characterize transient operation. The calibrated version of the model is then used to simulate operat
15、ion of the engine elsewhere in the operating envelope. Specific conditions must often be validated with test data, but it is extremely difficult to obtain flight test data at exactly the desired conditions. Flight conditions always vary from the desired conditions, therefore, a means of referring te
16、st data from actual conditions to desired conditions is necessary. 2. REFERENCES 2.1 Applicable Documents The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the
17、issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been ob
18、tained. SAE AIR5509 Page 3 of 9 2.1.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org. AS681 Gas Turbine Engine Performance Presentation for Computer Programs AS
19、755 Aircraft Propulsion System Performance Station Designation and Nomenclature ARP1210 Gas Turbine Engine Interface Test Data Reduction Computer Programs 2.2 Definitions ADDER: A value added to a parameter for adjusting a component characteristic. ENGINE: A gas turbine engine undergoing testing. EN
20、GINE DATA MATCH: Process of applying component-level scalars and adders or overall adjustments to the engine model to match the engine test data. ENGINEERING UNITS (EU) DATA: Data converted from raw electrical signals to measurement values in engineering units. Examples include pressure in pounds pe
21、r square inch and temperature in degrees Fahrenheit. This is the result of the Engineering Units Conversion process. ENGINE PROGRAM: Gas turbine engine performance program. INSTRUMENTATION: Devices used to convert physical measurements into electrical signals. MATCHED CYCLE MODEL: This represents a
22、Thermodynamic Engine Cycle Model which has had some form or level of Engine Data Match applied to it. Such models are used to predict engine performance, either in places where no testing was conducted or for future engines to be tested. Examples of possible use are: Development of power management
23、schedules Analysis of production engines, performance shifts, and field events Performance improvement studies Predicting a specific engine performance level MODIFIER: General term used for all scalars or adders calculated by or input to the program. PARAMETER: A datum that is used to describe an at
24、tribute in the engine or engine program. Examples: T41 or F041.Tt, P49 or F049.Pt, ALT or Amb.alt. RAW DATA: Electrical signals produced by instrumentation. SCALAR: A multiplier to a parameter for adjusting a component characteristic. THERMODYNAMIC ENGINE CYCLE MODEL: An algorithmic representation o
25、f an engine, typically composed of individual simplified component or process models, which are calculated in serial order, and whose degrees of freedom may be resolved through a linear-matrix algebraic method or solver. Such models typically represent gas-path average conditions only and do not inc
26、lude any explicit profile or annular representations. These models often include various modes of operation including steady-state, transient, and test-data analysis or matching capability. SAE AIR5509 Page 4 of 9 VALIDATION: The process of determining the accuracy of a given model. VERIFICATION: Th
27、e process of demonstrating that a model can perform its required functions with the acceptable fidelity. 3. FUNCTIONALITY The following processes are defined steps in acquiring and verifying test data for the purpose of matching an engine model. These processes may all be included in the order liste
28、d, but this is not necessary. Some companies will use a different order and may exclude or combine several of the processes. Figure 1 shows the process steps detailed in the following sections. FIGURE 1 - PROCESS MAP 3.1 Instrumentation Verification (Engine Not Running) Verify the instrumentation is
29、 installed correctly and functioning properly. 3.2 Raw Data Acquisition Acquire and store Raw Data during a test. This process may vary based on the kind of data being acquired (steady state versus transient). Instrumented Engine Verify Instrumentation (Engine not running) Acquire Raw Data (Engine r
30、unning) Verify Raw Data (Engine running) Convert to Engineering Units (EU Data) Verify EU Data Reduce EU Data (Data Reduction) Analyze Data Verify Reduced Data Develop Adjustments to Overall Performance Develop Engine Data Match Develop Component Refer Reduced Data to Reference Conditions Produce Ma
31、tched Cycle Model Report Engine Results Draw Conclusions SAE AIR5509 Page 5 of 9 3.3 Raw Data Verification (Engine Running) Verify instrumentation is functioning properly once an engine is operating and producing signals. This involves making sure all raw data signals are within an appropriate range
32、. 3.4 Engineering Units (EU) Data Conversion Convert the Raw Data into Engineering Units Data. Examples include: converting voltage measured by a pressure transducer into pounds per square inch and converting frequency measured by a speed sensor into revolutions per minute. 3.5 Engineering Units Dat
33、a Verification Ensure the Engineering Units Data meets certain minimum specifications. This normally involves checking for disconnected, mis-connected, dead, or connected but misreading instrumentation as well as ensuring the data is within a reasonable range, family or profile shape. 3.6 Engineerin
34、g Units Data Reduction Take EU Data and calculate engine cycle parameters, which may include overall performance. The calculations vary from simple averages of multiple measurements to execution of a Thermodynamic Engine Cycle Model using data inputs. 3.7 Data Analysis Analyze reduced data and calcu
35、lated cycle parameters to draw conclusions about engine performance based on that data. Analysis can include verification, comparison between engine data and a model, and calculation and understanding of overall and component-level engine performance. 3.7.1 Verify Reduced Data The Reduced Data is ve
36、rified by appropriate checks for the engine tested. A check might test if model is thermodynamically correct; are component efficiencies within expected ranges (must be less than 100% for example)? Are component performances what would be expected based on rig data? Is overall engine performance wha
37、t would be expected based on the engine family? 3.7.2 Develop Component Adjustments A Component Modifier will change the characteristic of a component in the engine program. Typical modifiers are adders or scalars on efficiency or airflow. The engine program may employ different analysis methods dep
38、ending on the engine cycle. As an example, core flow in a multi-shaft engine can be calculated several different ways. Core flow may be computed by assuming a fixed value for the high turbine flow function, by assuming a fixed value for the low turbine flow function, or by assuming known core nozzle
39、 flow characteristics. Although these are the more frequently used techniques, they do not exhaust the possible methods. Some programs offer switches that can be used to choose among available methods. Program suppliers are experienced in the effectiveness of the various analysis methods for evaluat
40、ing their hardware, and usually have selected preferred methods for their internal analyses. For Customer-adjustable models, the Supplier and Customer must coordinate which Component Modifiers will be available and the corresponding test measurements required. NOTE: It is preferred that a standard s
41、et of component modifier schemes be developed so the customer has a consistent, minimum set of data recording requirements, for example when flight testing multiple engine models on a given airplane model. SAE AIR5509 Page 6 of 9 3.7.3 Develop Adjustments to Overall Performance Calculate adjustments
42、 or correlations for use with a Thermodynamic Engine Cycle Model to produce a Matched Cycle Model. The method for producing this Engine Data Match will vary depending on available data, data quality, time requirements, and the final goal for the given model and associated data match. An Engine Data
43、Match may consist of some combination of component-level and overall adjustments. It may be representative of a single engine, or the minimum or average of a family of engines. It may also include a projection to future expectations based on hardware design changes for future introduction. 3.7.4 Dev
44、elop Engine Data Match After Component Modifiers have been applied to the model the Conformance Parameters output may be further adjusted to match test data by applying Data Closure and Transient Overshoot Modifiers. Data Closure Modifiers are used to match the engine program results for the Conform
45、ance Parameters to the measured or calculated data. Transient Overshoot modifiers are used to adjust the Conformance Parameters to reflect a worst case transient overshoot characteristic. Conformance Parameters refer to those engine characteristics for which the model is to be compared for conforman
46、ce. These may be engine characteristics indicated in certification limits and specification guarantees. The list below specifies typical Conformance Parameters used in a commercial turbofan engine. Other applications may require variations to this list. Fuel flow Gross thrust Net Installed Thrust EP
47、R or Engine Pressure Ratio, a parameter that may be used for setting engine power Low pressure shaft mechanical speed, a parameter that may also be used for setting engine power Intermediate pressure shaft mechanical speed High pressure shaft mechanical speed EGT or Exhaust Gas Temperature, a measur
48、e of the potential service margin of an engine CDT or Compressor Discharge Temperature RIT or Rotor Inlet Temperature ITT or Inter-Turbine Temperature 3.7.5 Refer Reduced Data to Reference Conditions Typically when an engine is tested, the actual boundary conditions are different than the desired in
49、tent or reference conditions. Therefore, the engine cycle data needs to be corrected for the difference. This is called “referring” the data from the actual test conditions to the desired reference conditions. This process is typically accomplished as part of the performance Data Reduction and may include corrections for ambient and flight conditions, reference customer power extraction, reference customer bleed, reference
