187 research outputs found

    Tip-Clearance Measurement in the First Stage of the Compressor of an Aircraft Engine

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    In this article, we report the design of a reflective intensity-modulated optical fiber sensor for blade tip-clearance measurement, and the experimental results for the first stage of a compressor of an aircraft engine operating in real conditions. The tests were performed in a ground test cell, where the engine completed four cycles from idling state to takeoff and back to idling state. During these tests, the rotational speed of the compressor ranged between 7000 and 15,600 rpm. The main component of the sensor is a tetrafurcated bundle of optical fibers, with which the resulting precision of the experimental measurements was 12 mu m for a measurement range from 2 to 4 mm. To get this precision the effect of temperature on the optoelectronic components of the sensor was compensated by calibrating the sensor in a climate chamber. A custom-designed MATLAB program was employed to simulate the behavior of the sensor prior to its manufacture.This work has been funded in part by the Fondo Europeo de Desarrollo Regional (FEDER); by the Ministerio de Economia y Competitividad under project TEC2015-638263-C03-1-R; by the Gobierno Vasco/Eusko Jaurlaritza under projects IT933-16 and ELKARTEK; and by the University of the Basque Country UPV/EHU under programmes UFI11/16 and Euskampus

    Design, Fabrication and Testing of a High-Sensitive Fibre Sensor for Tip Clearance Measurements

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    A highly sensitive fibre bundle-based reflective optical sensor has been designed and fabricated for Tip Clearance measurements in a turbine rig. The sensor offers high spatial and temporal resolution. The sensor probe consists of a single-mode transmitting fibre and two concentric rings of receiving multimode fibres that collect reflected light in a differential detection gain configuration, yielding a highly linear calibration curve for distance measurements. The clearance measurement range is approximately 2 mm around the central point fixed at 3.2 mm from the probe tip, and the sensitivity of the probe is 61.73 mm(-1). The fibre bundle has been designed to ensure that the distance security specifications required for the experimental program of the turbine are met. The optical sensor has operated under demanding conditions set by the blade and casing design. The experimental results obtained so far are promising and lead us to think that the optical sensor has great potential for online clearance measurements with high precision.This work was funded in part by the Fondo Europeo de Desarrollo Regional (FEDER), in part by the Ministerio de Economia y Competitividad under project TEC2015-638263-C03-1-R, and in part by the Gobierno Vasco/Eusko Jaurlaritza IT933-16 and ELKARTEK (KK-2016/0030, KK-2017/00033, KK-2017/00089 and KK-2016/0059). The work of Josu Amorebieta is supported in part by a PhD fellowship from the Universidad del Pais Vasco/Euskal Herriko Unibertsitatea (UPV/EHU), Vicerrectorado de Euskera y Formacion Continua

    Optical Fiber Sensor boosts aircraft engine monitoring

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    A reflective, intensity-modulated optical fiber sensor enables monitoring of tip clearance and tip timing in aircraft engines at low cost and high resolution.This work has been sponsored by the institutions Ministerio de Economía y Competitividad under project TEC2012-37983-C03; Gobierno Vasco/Eusko Jaurlaritza under projects IT664-13, S-PE13CA004, SPE13UN151, and S-PE12CA001; and by the University of the Basque Country (UPV/EHU) through program UFI11/16.Publicatio

    Advanced photonic sensors for industrial applications

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    380 p.En esta tesis se han desarrollado diversos sensores basados en fibra óptica cuya finalidad es ofrecer una alternativa o solución a las necesidades particulares de la industria. En este contexto, las fibras ópticas y la fotónica en general son especialmente atractivas gracias a características intrínsecas que poseen, como su pequeño tamaño y alta sensibilidad, por ejemplo, lo que ha aumentado el interés por parte del sector industrial en esta tecnología.En la primera parte de la tesis, se describe el proceso llevado a cabo para el diseño y fabricación de sensores ópticos para la medida sin contacto del parámetro llamado Tip Clearance (TC) en motores aeronáuticos. El TC consiste en medir la distancia (del orden de micrómetros) entre los álabes que están girando a altas revoluciones y la carcasa del motor, y, por tanto, es un parámetro de suma importancia para la industria aeronáutica tanto a nivel de seguridad como de eficiencia del motor. Dichos sensores fueron puestos a pruebas en el túnel de viento del Centro de Tecnologías Aeronáutcas (Zamudio, Bizkaia) con buenos resultados.En la segunda parte de la tesis se han diseñado y fabricado sensores basados en fibra multinúcleo particularizados específicamente para la medida de diversos parámetros como la temperatura,vibraciones, curvatura, bending, etc. que son de interés para la industria. Dichos sensores mostraron una alta sensibilidad, lo que unido a su simplicidad y pequeño tamaño los convierte en una alternativa interesante tanto para su integración en cadenas de producción como para su uso en test de validación

    Advanced photonic sensors for industrial applications

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    380 p.En esta tesis se han desarrollado diversos sensores basados en fibra óptica cuya finalidad es ofrecer una alternativa o solución a las necesidades particulares de la industria. En este contexto, las fibras ópticas y la fotónica en general son especialmente atractivas gracias a características intrínsecas que poseen, como su pequeño tamaño y alta sensibilidad, por ejemplo, lo que ha aumentado el interés por parte del sector industrial en esta tecnología.En la primera parte de la tesis, se describe el proceso llevado a cabo para el diseño y fabricación de sensores ópticos para la medida sin contacto del parámetro llamado Tip Clearance (TC) en motores aeronáuticos. El TC consiste en medir la distancia (del orden de micrómetros) entre los álabes que están girando a altas revoluciones y la carcasa del motor, y, por tanto, es un parámetro de suma importancia para la industria aeronáutica tanto a nivel de seguridad como de eficiencia del motor. Dichos sensores fueron puestos a pruebas en el túnel de viento del Centro de Tecnologías Aeronáutcas (Zamudio, Bizkaia) con buenos resultados.En la segunda parte de la tesis se han diseñado y fabricado sensores basados en fibra multinúcleo particularizados específicamente para la medida de diversos parámetros como la temperatura,vibraciones, curvatura, bending, etc. que son de interés para la industria. Dichos sensores mostraron una alta sensibilidad, lo que unido a su simplicidad y pequeño tamaño los convierte en una alternativa interesante tanto para su integración en cadenas de producción como para su uso en test de validación

    Analysis, design, fabrication and testing of an optical tip clearance sensor

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    Analyses and the design, fabrication, and testing of an optical tip clearance sensor with intended application in aircraft propulsion control systems are reported. The design of a sensor test rig, evaluation of optical sensor components at elevated temperatures, sensor design principles, sensor test results at room temperature, and estimations of sensor accuracy at temperatures of an aircraft engine environment are discussed. Room temperature testing indicated possible measurement accuracies of less than 12.7 microns (0.5 mils). Ways to improve performance at engine operating temperatures are recommended. The potential of this tip clearance sensor is assessed

    An Architecture for On-Line Measurement of the Tip Clearance and Time of Arrival of a Bladed Disk of an Aircraft Engine

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    Safety and performance of the turbo-engine in an aircraft is directly affected by the health of its blades. In recent years, several improvements to the sensors have taken place to monitor the blades in a non-intrusive way. The parameters that are usually measured are the distance between the blade tip and the casing, and the passing time at a given point. Simultaneously, several techniques have been developed that allow for the inferencefrom those parameters and under certain conditionsof the amplitude and frequency of the blade vibration. These measurements are carried out on engines set on a rig, before being installed in an airplane. In order to incorporate these methods during the regular operation of the engine, signal processing that allows for the monitoring of those parameters at all times should be developed. This article introduces an architecture, based on a trifurcated optic sensor and a hardware processor, that fulfills this need. The proposed architecture is scalable and allows several sensors to be simultaneously monitored at different points around a bladed disk. Furthermore, the results obtained by the electronic system will be compared with the results obtained by the validation of the optic sensor.Safety and performance of the turbo-engine in an aircraft is directly affected by the health of its blades. In recent years, several improvements to the sensors have taken place to monitor the blades in a non-intrusive way. The parameters that are usually measured are the distance between the blade tip and the casing, and the passing time at a given point. Simultaneously, several techniques have been developed that allow for the inferencefrom those parameters and under certain conditionsof the amplitude and frequency of the blade vibration. These measurements are carried out on engines set on a rig, before being installed in an airplane. In order to incorporate these methods during the regular operation of the engine, signal processing that allows for the monitoring of those parameters at all times should be developed. This article introduces an architecture, based on a trifurcated optic sensor and a hardware processor, that fulfills this need. The proposed architecture is scalable and allows several sensors to be simultaneously monitored at different points around a bladed disk. Furthermore, the results obtained by the electronic system will be compared with the results obtained by the validation of the optic sensor.This work has been funded in part by the Fondo Europeo de Desarrollo Regional (FEDER); by the Ministerio de Economia y Competitividad under project TEC2015-638263-C03-1-R; by the Gobierno Vasco/Eusko Jaurlaritza under projects IT933-16 and ELKARTEK (KK-2016/0030, KK-2017/00033, KK-2017/00089 and KK-2016/0059)

    Simulating eddy current sensor outputs for blade tip timing

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    Blade tip timing is a contactless method used to monitor the vibration of blades in rotating machinery. Blade vibration and clearance are important diagnostic features for condition monitoring, including the detection of blade cracks. Eddy current sensors are a practical choice for blade tip timing and have been used extensively. As the data requirements from the timing measurement become more stringent and the systems become more complicated, including the use of multiple sensors, the ability to fully understand and optimize the measurement system becomes more important. This requires detailed modeling of eddy current sensors in the blade tip timing application; the current approaches often rely on experimental trials. Existing simulations for eddy current sensors have not considered the particular case of a blade rotating past the sensor. Hence, the novel aspect of this article is the development of a detailed quasi-static finite element model of the electro-magnetic field to simulate the integrated measured output of the sensor. This model is demonstrated by simulating the effect of tip clearance, blade geometry, and blade velocity on the output of the eddy current sensor. This allows an understanding of the sources of error in the blade time of arrival estimate and hence insight into the accuracy of the blade vibration measurement

    Desarrollo de un sensor de fibra óptica para la medida del tip clearance y tip timing en motores aeronáuticos

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    163 p.Los sensores basados en fibra óptica son cada vez más utilizados en aeronáutica debido a las ventajas que presentan frente a sensores más tradicionales. En esta tesis se presenta el diseño y desarrollo de un sensor de fibra óptica para la medida del tip clearance y del tip timing en motores aeronáuticos. Este sensor está basado en la modulación de la luz reflejada por parte de los álabes de un motor aeronáutico en función de la distancia a la que se encuentran.En el capítulo 1 se realiza una introducción a los sensores de fibra óptica dedicando especial atención a que utilizan la modulación de la intensidad como principio de funcionamiento, y se explican los parámetros que serán objeto de medida por el sensor desarrollado en la presente tesis.En el segundo capítulo se presenta la metodología seguida en el diseño y desarrollo del sensor. Se definen los objetivos y requisitos iniciales que el sensor debe cumplir y los pasos seguidos hasta conseguirlo.En el tercer capítulo se muestran los resultados obtenidos para aplicaciones reales de funcionamiento del sensor diseñado. Se presentan los resultados conseguidos en dos entornos reales de trabajo. Por un lado, el túnel de viento que el Centro de Tecnologías Aeronáuticas posee en sus instalaciones de Zamudio (Vizcaya), y por el otro, el banco de ensayos con el que cuenta el Instituto Tecnológico de las Fuerzas Aéreas polacas en Varsovia (Polonia).Este documento concluye con un capítulo en el que se recogen las conclusiones del trabajo, así como las líneas futuras del mismo. También se enumeran los artículos (incluidos en un apéndice) en los que se basa la tesis, así como las conferencias y otras publicaciones realizadas durante este periodo

    Review of a Custom-Designed Optical Sensing System for Aero-Engine Applications

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    Fibre bundle-based reflective optical sensors are good candidates for parameter monitorisation in aero engines. Tip clearance is one of those parameters of great concern that is necessary to monitor. Within this optical technology, the evolution experienced by a custom-designed optical sensor is presented from its first configuration up to the fifth one. The performance of the last configuration is compared with those of other two optical sensors that are also based on a fibre bundle design. The comparison has been carried out in an experimental program in a transonic wind tunnel for aero engines. The proven high resolution and sensitivity of the last configuration of the optical sensor opens up the possibility to detect blade defects, cracks, etc. that could otherwise be hard to track.This work was supported in part by the European Regional Development Fund, in part by the Ministerio de Economía y Competitividad under project RTI2018-094669-B-C31, and in part by the Gobierno Vasco/Eusko Jaurlaritza under projects IT933-16, ELKARTEK (KK-2018/00078 and KK-2019/00051), EKINTZAILE 01560/2019 and HAZITEK (ZL-2020/00380). The work of J. Amorebieta is supported in part by a PhD fellowship from the University of the Basque Country (UPV/EHU), Vicerrectorado de Euskera y Formación Continua
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