METHOD OF MODELING, SIMULATION AND FAULT INJECTION FOR COMBINED HIGH PRESSURE GEAR PUMP FOR AEROENGINE

Abstract

The present invention belongs to the technical field of modeling and simulation of an aeroengine, and provides a method of modeling, simulation and fault injection for a combined high pressure gear pump for an aeroengine, which comprises: extracting the flow regions of a centrifugal pump and a gear pump in the aeroengine and merging into a combined flow region; dividing the combined flow region into different units according to a working principle; meshing each unit by a finite element analysis method, and setting boundary conditions and media parameters; simulating in Pumplinx to obtain the operation performance of the pumps, and adjusting the lateral clearance of the gear to debug the simulation model till a simulation error is within 5%; and then setting faults based on the debugged model to obtain the change of the operation performance of the pumps under the faults.

Claims

1. A method of modeling, simulation and fault injection for a combined high pressure gear pump for an aeroengine, comprising the following steps: S1. using UG to extract the flow regions of a centrifugal pump according to a three-dimensional model of the centrifugal pump S1.1 using UG to create a cylindrical entity comprising the flow regions of the centrifugal pump, and intersecting with the centrifugal pump to obtain a preliminary flow region; S1.2 trimming the preliminary flow region to remove the parts that do not belong to the flow region; S1.3 optimizing the flow region to remove a clearance between an inducer and an impeller; S1.4 dividing the flow region into different units according to the working principle, comprising four parts: an inlet unit, an inducer unit, an impeller unit and an outlet unit; firstly, creating a plane sheet which is flush with an inlet of a chamber of the inducer, and using the plane sheet to divide the flow region, with the inlet unit positioned above; then, creating a cylindrical sheet which is flush with an outlet of the chamber of the impeller, using the cylindrical sheet to divide the residual flow regions and separating out the outlet unit; then, creating a conical sheet having a vertex on a rotary shaft of the centrifugal pump, a surface between the impeller and the inducer and not intersecting with the teeth of the two gears, using the conical sheet to divide the residual flow regions and preliminarily separating the impeller part from the inducer part; finally, creating a plane sheet perpendicular to the rotary shaft of the centrifugal pump and higher than the bottom of the inducer, and using the plane sheet to divide the inducer part to obtain the plane sheet with an upper art as the inducer unit and a lower part which is merged with the impeller part to form the impeller unit; S2. using UG to extract the flow regions of a gear pump according to a three-dimensional model of the gear pump S2.1 using UG to create a cylindrical entity comprising the flow regions of the gear pump, and intersecting with the gear pump to obtain a preliminary flow region; S2.2 trimming the preliminary flow region to remove the parts that do not belong to the flow region of the gear pump; S2.3 optimizing the flow region, cutting and simplifying an inlet pipeline of the gear pump, and extruding at the inlet to generate a small cylinder to facilitate simulation settings; S2.4 dividing the flow region into different units according to the working principle, comprising five parts: an inlet unit, a gear unit, unloading groove units, expended high pressure area units and an outlet unit; firstly, creating a sheet which coincides with a gear cavity wall and penetrates through the flow region of the gear pump, and using the sheet to divide the flow region to obtain the inlet unit and the outlet unit; then, creating plane sheets which are respectively flush with the upper surface and the lower surface of the gear, and using the two sheets to divide the residual flow regions to obtain the gear unit; finally, creating a sheet which coincides with the outer wall surface of an unloading groove, and using the sheet to divide the residual flow regions to obtain four unloading groove units and eight expended high pressure area units; S3. merging the flow regions of the centrifugal pump and the gear pump to form a combined flow region S3.1 extracting the flow region of a lower connecting pipeline of the centrifugal pump in the model; S3.2 importing the flow region of the centrifugal pump, the flow region of the gear pump, and the flow region of the connecting pipeline into a model file; rotating and translating the flow region of the gear pump till the inlet of the gear pump is parallel to the outlet of the connecting pipeline and the center of a circle of the outlet of the connecting pipeline is on the centerline of the small cylinder at the inlet of the gear pump; S3.3 creating a round table between the inlet of the gear pump and the outlet of the connecting pipeline to connect the flow region of the gear pump and the flow region of the connecting pipeline; S3.4 merging the inlet unit of the gear pump, the flow region of the connecting pipeline and the outlet unit of the centrifugal pump as a combined flow region model; S4. importing the combined flow region model into Pumplinx for creating a simulation model S4.1 importing a combined pump flow region model into pumplinx and establishing four monitoring points, i.e., a rotary center of a gear pump driving gear, a rotary center of a slave gear, a combined pump inlet and a combined pump outlet; S4.2 scaling x, y and z directions of the combined flow region model till the positions of the monitoring points coincide with the actual positions, and unifying the unit; S4.3 performing the Split Disconnected operation on the combined flow region, dividing the combined flow region into different units according to the modes in S1.4 and S2.4, and creating a Surface for each unit in sequence; S4.4 meshing each unit, using a rotor template mesher for the meshing of the gear unit, and using an ordinary mesher for the meshing of the other units; S4.5 arranging interfaces for connected units, comprising an inlet unit and an inducer unit, an inducer unit and an impeller unit, an impeller unit and a connecting unit of the centrifugal pump and the gear pump, a gear unit and a connecting unit of the centrifugal pump and the gear pump, a gear unit and an outlet unit, a gear unit and an unloading groove unit, a gear unit and an expended high pressure area unit, and an unloading groove unit at an outlet side and an expended high pressure area unit; S4.6 adding modules, comprising Axial Flow, Centrifugal and Gear three rotor modules and Turbulence, Cavitation, Heat, Streamline and Particle modules, and setting parameters of the modules; S4.7 setting boundary conditions; S4.8 setting media parameters; S5. debugging the simulation model and adjusting the lateral clearance of the gear for different working conditions till the errors between the simulation results and the experimental data are within 5%; S6. conducting fault injection on the simulation model under a rated state S6.1 selecting the simulation model under the rated state for fault injection; and selecting model fault parameter setting manners for three fault modes of no pressurization of centrifugal pump outlet fuel, reduced pressurization of centrifugal pump outlet fuel, and reduced flow of gear pump fuel supply; S6.2 for no pressurization fault of centrifugal pump outlet fuel, setting rotary speed of the impeller and the inducer as 0 in Pumplinx for simulation; S6.3 for reduced pressurization fault of centrifugal pump outlet fuel, respectively thickening the corresponding flow regions of the inducer and the impeller in UG to increase the clearance; S6.4 for reduced flow fault of gear pump fuel supply, thinning the teeth of the gear in UG to increase the radial clearance; when meshing the gear unit in Pumplinx, increasing the lateral clearance, i.e., the value of Side Leakage Gap; S7. respectively simulating the simulation model under each fault to obtain the change of pump performance under each fault.

Description

DESCRIPTION OF DRAWINGS

[0039] FIG. 1 is a flow chart of a method of modeling, simulation and fault injection for a combined high pressure gear pump for an aeroengine;

[0040] FIG. 2 is a flow chart of extracting a pump flow region;

[0041] FIG. 3 is a flow chart of merging flow regions;

[0042] FIG. 4 is a model diagram of a combined flow region;

[0043] FIG. 5 is a flow chart of creating Pumplinx simulation model;

[0044] FIG. 6 is a simulation outlet flow-time relationship diagram under a fault that rotary seed of an impeller and an inducer is 0;

[0045] FIG. 7 is a simulation outlet flow-time relationship diagram under a fault that a radial clearance is increased to 0.45 mm; and

[0046] FIG. 8 is a simulation outlet flow-time relationship diagram under a fault that a lateral clearance is increased to 0.1 mm.

DETAILED DESCRIPTION

[0047] The present invention is further described below in combination with the drawings. The present invention replies on the background of a three-dimensional model and experimental data of a fuel pump of a certain type of aeroengine. A method flow of modeling, simulation and fault injection for a combined high pressure gear pump for an aeroengine is shown in FIG. 1.

[0048] FIG. 2 is a flow chart of extracting a pump flow region. The steps of extracting the flow region of the centrifugal pump are as follows:

[0049] S1. using UG to create a cylindrical entity including the flow regions of the centrifugal pump, and intersecting with the centrifugal pump to obtain a preliminary flow region;

[0050] S2. trimming the preliminary flow region, creating a cylindrical entity having the same diameter as the rotary shaft, subtracting the cylindrical entity and the flow region, and remove the middle rotary shaft part; creating a cylindrical entity having the same diameter as a housing below the impeller, subtracting the cylindrical entity and the flow region and making the clearance value below the impeller as 0.15 mm; removing other parts which do not belong to the flow region step by step through the commands of extrude, TrimBody and subtract;

[0051] S3. optimizing the flow region to remove a clearance between an inducer and an impeller; creating a cylindrical sheet having the same inner diameter as the bottom of the inducer; dividing the flow region part and removing the clearance after dividing; merging the residual divided parts to the flow region;

[0052] S4. dividing the flow region of the centrifugal pump into different units according to the working principle, including four parts: an inlet unit, an inducer unit, an impeller unit and an outlet unit; firstly, creating a plane sheet which is flush with an inlet of a chamber of the inducer, and using the sheet to divide the flow region, with the inlet unit positioned above; creating a cylindrical sheet which is flush with an outlet of the chamber of the impeller, using the sheet to divide the residual flow regions and separating out the outlet unit; creating a conical sheet having a vertex on a rotary shaft of the centrifugal pump, a surface between the impeller and the inducer and not intersecting with the teeth of the two gears, using the sheet to divide the residual flow regions and preliminarily separating the impeller part from the inducer part; creating a plane sheet perpendicular to the rotary shaft of the centrifugal pump and slightly higher than the bottom of the inducer, and using the sheet to divide the inducer part to obtain the sheet with an upper art as the inducer unit and a lower part which is merged with the impeller part to form the impeller unit.

[0053] The steps of extracting the flow region of the gear pump are as follows:

[0054] S1. using UG to firstly create a cylindrical entity including the flow regions of the gear pump, and intersecting with the gear pump to obtain a preliminary flow region;

[0055] S2. trimming the preliminary flow region to remove the parts that do not belong to the flow region of the gear pump;

[0056] S3. optimizing the flow region, cutting and simplifying an inlet pipeline of the gear pump, and extruding at the inlet to generate a small cylinder to facilitate simulation settings;

[0057] S4. dividing the flow region into different units according to the working principle, including five units: an inlet unit, a gear unit, unloading groove units, expended high pressure area units and an outlet unit; firstly, creating a sheet which coincides with a gear cavity wall and penetrates through the flow region of the gear pump, and using the sheet to divide the flow region to obtain the inlet unit and the outlet unit; creating plane sheets which are respectively flush with the upper surface and the lower surface of the gear, and using the two sheets to divide the residual flow regions to obtain the gear unit; creating a sheet which coincides with the outer wall surface of an unloading groove, and using the sheet to divide the residual flow regions to obtain four unloading groove units and eight expended high pressure area units.

[0058] FIG. 3 is a flow chart of merging flow regions. The steps of merging flow regions are as follows:

[0059] 51. extracting the flow region of a lower connecting pipeline of the centrifugal pump in the model;

[0060] S2. importing the flow region of the centrifugal pump, the flow region of the gear pump, and the flow region of the connecting pipeline into a model file; rotating and translating the flow region of the gear pump till the inlet of the gear pump is parallel to the outlet of the connecting pipeline and the center of a circle of the outlet of the connecting pipeline is on the centerline of the small cylinder at the inlet of the gear pump;

[0061] S3. creating a round table between the inlet of the gear pump and the outlet of the connecting pipeline to connect the flow region of the gear pump and the flow region of the connecting pipeline;

[0062] S4. merging the inlet unit of the gear pump, the flow region of the connecting pipeline and the outlet unit of the centrifugal pump.

[0063] FIG. 4 is a model diagram of a combined flow region which is finally formed.

[0064] FIG. 5 is a flow chart of creating Pumplinx simulation model. The steps of creating Pumplinx simulation model are as follows:

[0065] 51. importing a combined pump flow region model into pumplinx and establishing four monitoring points, i.e., a rotary center of a gear pump driving gear, a rotary center of a slave gear, an inlet and an outlet;

[0066] S2. scaling x, y and z directions of the model according to a scale factor of 0.001, and making the positions of the monitoring points coincide with the actual positions, and then completing the unifying of the unit;

[0067] S3. performing the Split Disconnected operation on the flow region, dividing the flow region into different units, and creating a Surface for each unit in sequence; creating three Surfaces of inlet_inlet, inlet_mgi_youdao and inlet_walls for the inlet unit; creating four Surfaces of youdao_mgi_inlet, youdao_mgi_yelun, youdao and youdao_walls for the inducer unit; creating five Surfaces of yelun_mgi_youdao, yelun_mgi_connect, yelun, yelun_bot and yelun walls for the impeller unit; creating four Surfaces of connect_mgi_yelun, connect_mgi_drive, connect_mgi_slave and connect_walls for the connecting unit of the centrifugal pump and the gear pump; creating six Surfaces of gear_drive_shroud, gear_slave_shroud, gears_outer_top, gears_outer_bottom, gears_drive and gears_slave for the gear unit; creating two Surfaces of relief top inlet_mgi gears and relief top inlet_walls for the unloading groove unit above the inlet of the gear pump, the same for the unloading groove unit below the inlet of the gear pump; creating four Surfaces of relief top outlet_mgi gears, relief top outlet_mgi_expand1, relief top outlet_mgi_expand2 and relief top outlet_walls for the unloading groove unit above the outlet of the gear pump, the same for the unloading groove unit below the outlet of the gear pump; respectively creating three Surfaces of expand_bottom_drive_mgi_gears, expand_bottom_drive_mgi_relief and expand_bottom_drive_walls for four expended high pressure area units; creating four Surfaces of outlet_mgi_drive, outlet_mgi_slave, outlet_outlet and outlet_walls for the outlet unit;

[0068] S4. conducting meshing; using a rotor template mesher for the gear unit; selecting External Gear as the rotor type, selecting Advanced Mode as the setting mode; making the gap inner radius and the gap outer radius as 27.05 mm and 41.7 mm respectively; for a vortex chamber part, when meshing, setting a maximum cell size as 0.01 and setting a cell size on surfaces as 0.005; for other units, when meshing, setting the maximum cell size as 0.02 and setting the cell size on surfaces as 0.01; integrating some small broken surfaces that appear during meshing to adjacent surface meshes by using Combine function in Split/Combine Geometry or Grid;

[0069] S5. arranging interfaces for connected units, comprising an inlet unit and an inducer unit, an inducer unit and an impeller unit, an impeller unit and a connecting unit of the centrifugal pump and the gear pump, a gear unit and a connecting unit of the centrifugal pump and the gear pump and an outlet unit, a gear unit and an unloading groove and an expended high pressure area, an unloading groove and an expended high pressure area at an outlet side;

[0070] S6. adding modules, comprising Axial Flow, Centrifugal and Gear three rotor modules and Turbulence, Cavitation, Heat, Streamline and Particle modules; arranging an axial flow corresponding inducer, and setting number of blades as 5, coordinates of a rotor center as [0 0 0] with counterclockwise rotation, and a rotational axis vector as [0 0 1]; arranging a centrifugal corresponding impeller, and setting number of blades as 18, coordinates of a rotor center as [0 0 0] with counterclockwise rotation, and a rotational axis vector as [0 0 1]; setting the number of teeth of the driving gear and the slave gear as 16 with counterclockwise rotation and a rotational axis vector as [0 0 1]; selecting the gear pump as a reference pump, number of revolutions as 10 and time steps per drive gear tooth rotation as 30;

[0071] S7. setting boundary conditions; setting the boundary surface youdao as the axial rotor and changing corresponding option of Axial Flow as Rotor; setting the boundary surface yelun as the centrifugal rotor and changing corresponding option of Centrifugal as Rotor; setting inlet pressure for the boundary surface inlet_inlet, changing corresponding option of Axial Flow as Inlet, and inputting an inlet pressure value; setting outlet pressure for the boundary surface outlet_outlet, changing corresponding option of Gear as Outlet, and inputting an outlet pressure value;

[0072] S8. setting media parameters which are shown in Table 1.

TABLE-US-00001 TABLE 1 Table of Media Parameters and Values Media Parameters Values Dynamic Viscosity 0.001154 Pa .Math. s Density 780 kg/m3 Liquid Bulk Modulus(B0) 1.5 109 Pa Linear Bulk Modulus(B1) 0 Liquid Reference Pressure 101325 Pa Saturation Pressure 3000 Pa Heat Capacity 4180 J/kg .Math. K

[0073] Eight states shown in Table 2 are simulated, and the simulation model is debugged by adjusting the lateral clearance of the gear to obtain comparison of simulation results and experimental data as shown in Table 3. The errors are within 5%.

TABLE-US-00002 TABLE 2 Boundary Conditions of Eight States Boundary Conditions Rotary Centrifugal Pump Gear Pump Speed Inlet Pressure Outlet Pressure States (r/min) (MPa) (MPa) 1 6250 0.345 2.896 2 6250 0.345 7.895 3 3000 0.345 1.4 4 3000 0.345 6.9 5 4000 0.345 1.4 6 4000 0.345 8.3 7 5000 0.345 2.8 8 5000 0.345 9

TABLE-US-00003 TABLE 3 Comparison of Outlet Flow Simulation Results and Experimental Data Experimental Data Simulation Results States (kg/s) (kg/s) Error 1 3.1778 3.25 2.27% 2 3.0922 3.23 4.46% 3 1.5083 1.48 1.88% 4 1.4417 1.38 4.27% 5 2.03 2.07 1.97% 6 1.9161 1.825 4.75% 7 2.5417 2.525 0.66% 8 2.3714 2.375 0.15%

[0074] FIGS. 6-8 show model simulation results under various faults. The steps of fault injection are as follows:

[0075] S1. selecting the simulation model under the rated state for fault injection; and selecting a model fault parameter setting manner for three fault modes of no pressurization of centrifugal pump outlet fuel, reduced pressurization of centrifugal pump outlet fuel, and reduced flow of gear pump fuel supply, as shown in Table 4;

TABLE-US-00004 TABLE 4 Fault Mode and Corresponding Model Fault Parameter Setting Manner Fault Mode Model Fault Parameter Setting Manner No pressurization of The rotary speed of the centrifugal pump outlet fuel centrifugal pump is 0 Reduced pressurization The clearance between the of centrifugal pump inducer and the housing is outlet fuel increased The clearance between the impeller and the housing is increased Reduced flow of gear pump The radial clearance is fuel supply increased The lateral clearance is increased

[0076] S2. for no pressurization fault of centrifugal pump outlet fuel, setting rotary speed of the impeller and the inducer as 0 in Pumplinx for simulation to obtain fuel pump outlet flow of 1.8 kg/s, as shown in FIG. 6;

[0077] S3. for reduced pressurization fault of centrifugal pump outlet fuel, respectively thickening the corresponding flow regions of the inducer and the impeller in UG to increase the clearance; when simulating to obtain an increase of 1.5 mm in the clearance between the inducer and the housing, the centrifugal pump outlet pressure being 0.75 MPa, and when increasing the clearance between the impeller and the housing by 1 mm, the centrifugal pump outlet pressure being 1.0 MPa;

[0078] S4. for reduced flow fault of gear pump fuel supply, thinning the teeth of the gear in UG to increase the radial clearance; when the clearance is 0.45 mm, simulating to obtain fuel pump outlet flow of 2.7925 kg/s, as shown in FIG. 7; when meshing the gear unit in Pumplinx, increasing the value of Side Leakage Gap; and when the clearance is 0.1 mm, the fuel pump outlet flow being 2.774 kg/s, as shown in FIG. 8.