Maintenance costs are a substantial contributor to airline operating costs. In this context, understanding, analyzing, and predicting engine performance deterioration is crucial. While diagnostic methods for analyzing the current module and overall engine condition are established in state-of-the-art engine condition monitoring (ECM) systems, deterioration modeling and prognosis are still fields of research. The identification of the contribution of deterioration mechanisms, such as fouling, erosion, and abrasion, to the in-service deterioration poses a key challenge in this area. This paper focuses on a top-down approach for the high pressure compressor (HPC) module. The selected approach is to quantify the contribution of individual deterioration mechanisms to the overall HPC efficiency deterioration based on in-flight measurements. This is accomplished by first using the in-flight measurements to analyze the HPC efficiency loss. Then, the resulting time series of the analyzed HPC efficiency loss are preprocessed. Finally, models of the deterioration mechanisms are fitted to the preprocessed time series. The deterioration models are chosen based on literature references to the respective deterioration mechanisms. As multiple influencing factors affect the deterioration mechanisms, a fleet analysis is conducted to select the model inputs. The fitting process involves a parametric nonlinear regression problem. The outcome is an estimation of the evolution of the deterioration mechanisms over time. This methodology is used to evaluate all available in-service engines of the same type and fleet and to define a fleet model. In the final step, benefits and limitations of the fleet model are investigated.
To ensure the quality standards in engine testing, a growing research effort is put into the modeling of full engine test cell systems. A detailed understanding of the performance of the combined system, engine and test cell, is necessary e.g. to assess test cell modifications or to identify the influence of test cell installation effects on engine performance. This study aims to give solutions on how such a combined engine and test cell system can be effectively modeled and validated in the light of maximized test cell observability with minimum instrumentation and computational requirements. An aero-thermodynamic performance model and a CFD model are created for the Fan-Engine Pass-Off Test Facility at MTU Maintenance Berlin-Brandenburg GmbH, representing a W-shape configuration, indoor Fan-Engine test cell. Both models are adjusted and validated against each other and against test cell instrumentation. A fast-computing performance model is delivering global parameters, whereas a highly-detailed aerodynamic simulation is established for modeling component characteristics. A multi-disciplinary synthesis of both approaches can be used to optimize each of the specific models by calibration, optimized boundary conditions etc. This will result in optimized models, which, in combination, can be used to assess the respective design and operational requirements.
This paper describes research carried out in the European Commission co-funded project E-BREAK (Engine BREAK through components and subsystems) focused on development of generic enabling technologies for new aero-engines. A global market forecast (2015–2034) from Airbus [1], depicts an average growth rate of 4.6% per year. Air traffic is forecasted to double in the next 15 years. It is expected, to triple in the next 20 years, according to the speech given by RRUK CEO during the Aerodays 2015 in London [2]. This high level of growth in demand for air travel represents huge opportunities as well as significant challenges for the aerospace industry. Research and Technology through collaborative European projects addresses the environmental penalties of air traffic. Europe’s aviation industry therefore faces a huge challenge to satisfy the demand whilst guaranteeing competitiveness, safety and more environmentally friendly air travel. Innovative engine configurations consequently need to be investigated in order to reduce significantly the pollutant emissions (15 to 20% for fuel consumption and CO2 and 80% reduction for NOx). Such reductions can only be achieved by considering innovative components that could be integrated and optimized in new engine configurations. In response to the above demands, aero-engine manufacturers are constantly aiming to improve gas turbine efficiency for two main reasons: to reduce environmental impact and to minimize operating costs. The E-BREAK project is aimed at the development of generic enabling technologies needed to address the challenges for future engines with higher overall pressure ratios (OPR) and bypass ratio (BPR). These technologies are developed at subsystem and component level and validated in test rigs which are equivalent to Technical Readiness Level (TRL) 5. The utility of the developed technologies are assessed using four standard study powerplants. These are turboshaft, regional turbofan, mid-size open rotor, and large turbofan, covering most of the expected future commercial aero-engine market. This article describes the technical approach followed in E-BREAK for the various technologies being investigated, these are: • Advanced sealing to reduce oil and air leakages • Variability control to ensure stability of thermodynamic cycle • High temperature resistant material and abradables to prevent fast degradation at high temperatures • Light material to prevent significant mass increase • Health monitoring system to anticipate sub-systems degradation The envisaged outcomes from E-BREAK are enablers to other EU-funded research projects focused on module maturation progress, such as LEMCOTEC dealing with high OPR modules and ENOVAL dealing with high BPR LP components.
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