Download For Airbus Helicopter

For Airbus Helicopter
Qualified ISO 9001:2011
COMPANY FOUNDATION 1987
Areas of initial production
• Plastic extruder, hydraulic turbines and
rolling mills gearboxes
• High speed gearboxes for gas and steam
turbines.
• Special purpose gearboxes for the
marine, industrial and aerospace sectors
• Specialized in custom equipment and
prototypes
• Test bench for Agusta Westland, AVIO,
Ferrari Corse, Aermacchi.
In year 2000, company ownership changes to actual
status
• China sector opens for industrial applications
and universal shafts
Universal shaft up to
9.000 kNm transmissible
torque
Gearboxes up to 100 ton
for rolling mills
CAT now develops test stands for
• Agusta Westland
• AVIO (Previously FIAT AVIO)
• Ferrari Corse
• Aermacchi
• A.B.B. Power and Automation
• Universities (Politecnico di Milano,
Università degli Studi di Pisa)
• Indipendent companies (AVIATEST, AM
Testing)
•
Design and engineering are made in the main
workshop in Cerro Maggiore (near the airport of •
•
Malpensa).
Engineering, gear sizing and structural calculations •
•
and design of control system are made and
•
verified internally by C.A.T.
Outsourcing from long-term, qualified partners •
under a strict supervision allows to multiply the •
company’s production capabilities
Drawings
Steel structures
Gears
Electrical drives
Hydraulic equipment
Finite element analysis
Acquisition and order analysis systems
Special sensors, strain gauges installation,
material analysis
This flexible structure allows to handle
even multiple large projects at the
same time.
C.A.T. was able to A.B.B. an electrical
back to back test stand for a 30 MW
motor (final weight 96000 kg) in 8
months from order while delivering a
multi-purpose Combiner-Gear Test
Bench for Agusta Westland at the
same time .
DESIGN AND CONSTRUCTION OF
GEARBOXES
MECHANICAL COMPONENTS
SPECIAL COUPLINGS
CUSTOM SLIP BEARINGS
TILTING PADS BEARINGS
UNIVERSAL SHAFTS
INTEGRATED SYSTEM
TURN KEY TEST BENCH
STANDARD DEVELOPMENT TREE
1. UNDERSTAND THE TEST REQUIREMENTS
2. DEVELOP A TECHNICAL SPECIFICATION
1. DEFINE LOAD APPLICATION DEVICE
2. DEFINE CONTROL STRATEGY
3. PRELIMINARY LAYOUT AND STUDY
1. MOTOR/POWER SIZING
2. GEARS AND SHAFTS VERIFICATIONS
3. LOAD SYSTEM ENGINEERING
4. DEFINE SENSORS AND DAQ
5. QCP DEFINITION
4. CRITICAL DESIGN REVIEW
1. FINAL DRAWINGS AND DETAIL CALCULATIONS
2. PROJECT DOCUMENTATION
5. PRODUCTION PHASE
1. QUALITY CONTROL AND CERTIFICATION
2. INTERNAL TESTS OF CRITICAL COMPONENTS
6. ON SITE INSTALLATION AND FINAL TESTS
7. AS BUILT DOCUMENT UPDATE
TOOLS
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EXPERIENCE
SIMILAR PROJECTS
DESIGN NORMS
SPECIFIC SOFTWARE
2D AND 3D CAD
FEM ANALYSIS
DETAILED PLANNING
NDT
SPECIFIC TESTS
DEDICATED TEST AREA WITH
FORCED LUBRICATION AND
ELECTRIC MOTOR UP TO 360
kW 3000 rpm
EXTENSIVE SENSOR SUITE
DEDICATED TO TEST
VALIDATION
a M
S
C
b M
(GEARBOX)
S
C
(GEARBOX)
TEST ITEM
S
C
EXTERNAL
LOAD
ITEM NORMAL
LOAD (ROTOR)
SAFETY COUPLING (actual position depends on application)
THE TEST ITEM IS DIRECTLY CONNECTED TO A BRAKING /LOAD UNIT (a),
OR IS SIMPLY DRIVEN AND THE NORMAL OPERATION GUARANTEES THE LOAD (b). THIS IS
THE SIMPLEST WAY TO APPLY TORQUE.
GEARBOX IS NEEDED VOR VERY LOW OR HIGH SPEED
EXAMPLES: WATER BRAKE (a), WHIRL TOWER TEST (b)
POSITIVE
EASIER TO DESIGN AND MANUFACTURE COMPARED TO CLOSED CIRCUIT BENCH
SIMPLE CONTROLS
NEGATIVE
HIGH ENERGY COST , LARGE SIZE MOTOR
HIGH LOAD REQUIRE MEDIUM VOLTAGE MOTORS AND DEDICATED POWER LINES.
M
TEST ITEM 1
WATER BRAKE GIVES
LOAD
TEST ITEM 2
WATER BRAKE
TEST ITEM 1 ACTS AS
REDUCER
ELECTRIC MOTOR
M
TEST ITEM 2 INCREASES
SPEED FOR WATER BRAKE
TEST ITEM 1: LOAD GIVEN
FROM AERODYNAMIC
FORCES
TEST ITEM 2: TORQUE
GIVEN TO TEST ITEM 2
FROM TEST ITEM 1
M
MULTIPLIER TO REACH
ITEM NOMINAL SPEED
ELECTRIC MOTOR
CAT SUPPLIED
• GEARBOX COMPLETE
WITH LUBRICATION UNIT
AND JB
• LONG AND SHORT SHAFT
• MANNER TORQUE METER
• DRIVE AND ELECTIC
MOTOR
• START UP, INSTALLATION,
ALIGNMENT AND
ENGINEERING
CONSULENCE ON SITE
• PITCH CONTROL SYSTEM
(PCS)
• ALARM INTEGRATION
• HBM DAQ SYSTEM
SETTING CONSULENCE
WITH HBM SPECIALIST
Slip bearings gearbox
Safety coupling
Overpressure chamber for non-ATEX torque meter
150 kW 25000 rpm test bench for GST (final customer AVIO) to test a cryogenic pump in ATEX IIG
environment (pump works with liquid methane). In this machine the resistance is given by the liquid
medium resistance going through the pump
Roller bearings gearbox
5000 to 16000 rpm
Slip bearings gearbox
16000 to 80000rpm
Test monitored values
Safety coupling
200 kW 5000 rpm-80000 rpm test bench for GST (final customer AVIO) to test cryogenic bearings in
ATEX IIG environment (bearings lubricated with liquid methane). As above, the resistance is given by
the liquid medium going through the test item
M
S
C
(GEARBOX)
TEST ITEM
(GEARBOX)
S
C
POWER RICIRCULATION
THE MOTOR AND THE GENERATOR ARE MECHANICALLY AND ELECTRICALLY CONNECTED.
MOTOR IS VELOCITY CONTROLLED. THE GENERATOR IS POWER CONTROLLED.
RESULTING ELECTRICAL POWER RICIRCULATION CREATES TORQUE OVER THE TEST ITEM.
GEARBOXES ARE USED TO SYNCHRO THE ITEM SPEED WITH MOTOR /GEN SPEED.
POWER CONSUMPTION IS EQUAL TO THE SUM OF INTERNAL LOSSES.
SINGLE MOTOR<1MW
LOW VOLTAGE (400V)
CAN USE STANDARD POWER GRID
SINGLE MOTOR>1MW
MEDIUM VOLTAGE OR HIGH VOLTAGE
REQUIRES DEDICATED TRANSFORMER
POSITIVE
STANDARD COMMERCIAL PARTS
EASY MECHANICAL DESIGN
NEGATIVE
HIGH INERTIA (BIGH ROTORS)
PRECISE TORQUE CONTROL REQUIRES A
METICOLOUS ELECTRICAL/CONTROL DESIGN
G
ABB MOTOR BACK TO BACK TEST BENCH
1800 RPM 21 MW – CESI TEST FIELD 1
• RIGID SHAFT CONNECTION
1800 RPM 21 MW – CESI TEST FIELD 1
• FLEX PACK CONNECTION
• INDIPENDENT AUTOMATED LUBRICATION
UNITS
• ALIGNMENT SERVICE (0,1° TOLERANCE)
• CRITICAL DRIVE TRAIN FREQUENCIES STUDY
• TEST SUPPORT FOR VIBRATION ANALYSIS.
ABB MOTOR BACK TO BACK TEST
1800 RPM 37 MW CESI TEST FIELD
2
• FLEX PACK COUPLING AND
INTEGRATED SAFETY SYSTEM
• INDIPENDENT AUTOMATED
LUBRICATION UNITS
• ALIGNMENT SERVICE (0,1°
TOLERANCE)
• CRITICAL DRIVE TRAIN
FREQUENCIES STUDY
• TEST SUPPORT FOR VIBRATION
ANALYSIS
LAYOUT CONCEPTION
AND DETAILED POSITIONING
STUDY
(LUBRICATION NOT SHOWN)
FINAL INSTALLATION AND GEARBOX
SPLIT OPEN SHOWING GEAR
MESHING
LUBRICATION WITH PLC CONTROL
FOR LEVEL AND TEMPERATURE (700
L/MIN)
STARTING FROM A CUSTOMER
DESIGN, THIS BENCH ENGINEERING
WAS REVISED, UPDATED AND
IMPROVED TO HAVE A MGB TEST
BENCH OPERATIVE IN A TIME
WINDOW OF 5 MONTHS ONLY.
GEARBOX ENGINEERING WAS MADE
USING MODERN PRODUCTION
METHODS, GEARS CALCULATION
ACCORDING AGMA 2101-D04 AND
AGMA 6011-I03 FOR HIGH SPEED
THE USE OF STANDARD DESIGN AND
INDUSTRILA COMPONENTS AND
PRACTICES LOWERED DEVELOPEMENT
TIME AND PRODUCTION TIME AND
ALOWED TO KEEP THE TIME SCHEDULE
REGENERATIVE TEST BENCH FOR SMALL HELICOPTER TRANSMISSION
COUNTER ROTATING SHAFTS
INPUT SPEED 1500 rpm POWER 2 x 700 Kw
OUTPUT SPEED 1000 rpm POWER 2 x 650 Kw
CAT ENGINEERED AND SUPPLIED
• 4 GEARBOXES
• 8 COUPLINGS AND 4 SAFETY COUPLINGS
• 2 MAST LOADING SYSTEM
• LUBRICATION
• ASSEMBLY SUPERVISION
CONTROL UNIT
G
M
TEST ITEM
M
THE TORQUE IS APPLIED BY THE TWO GENERATORS REGULATING THE POWER
ABSORPTION. THE TWO UPPER UNITS MUST ALWAYS APPLY THE SAME
TORQUE WITH VERY SMALL OSCILLATIONS TO AVOID PREMATURE WEAR OF
THE GEARS.
G
USING LINEAR ACTUATORS IS
POSSIBLE TO EMULATE THE LOAD
EFFECT OF ROTOR OVER THE
TRANSMISSION. ON A STANDARD
HELICOPTER THERE WILL BE A SINGLE
LOAD SYSTEM ON THE MAST AND
MAYBE ONE ON TAIL ROTOR IF
TESTED WITH MGB. ON A COUNTER
ROTATING MAST (KAMOV) THE
SYSTEMS ON THE MAST WILL BE TWO
AND LOAD SHALL BE BALANCED TO
AVOID ASYMMETRIC GEAR WEAR
DURING TESTS.
ACTUATORS CAN BE ELECTRICAL OR
HYDRAULIC
G
TEST ITEM
M
M
CAN WORK AT 90° TILTED POSITIONS
23000 AND 7000 rpm OUTPUT
TWIN MOTOR INPUT, 1500 rpm1MW EACH (2 MW POWER)
TESTED AT YEOWIL IN 2011.
A SPECIFIC DESIGN FOR THE LUBRICATION WAS REQUIRED TO ALLOW THE 90° TILTED
OPEARATION, USING A SUCTION PUMP TO DRAIN OIL FROM THE HIGH SPEED STAGE. THE
MACHINE FRAME WAS ADAPTED TO THE USE OF AN EXISTING BENCH IN YEOWIL WHICH
HAD A 6° VERTICAL INCLINATION.
THE MECHANICAL LOOP APLLIES THE
TORQUE INSIDE THE CLOSED
MECHANICAL CIRCUIT
M
FIRST TYPE: TORQUE APPLIED BY A
HYDRAULIC ROTATING CHAMBER
INSIDE THE LOOP
P
TEST ITEM
M
LD
SECOND TYPE: TORQUE
APPLIED BY AN ELECTRIC
DRIVE WORKING ON A
PLANETARY GEARBOX
INSIDE THE LOOP
16000 rpm
8000 rpm
MULTI PURPOSE CLOSED MECHANICAL LOOP TEST BENCH COMBINER GEARBOX FOR DUAL ROTOR
HELICOPTER. THE COMBINER TAKES THE INPUT FROM THE TWO TURBINES AND REDIRECTS AND
SINCHRONYZES THE TWO LIFT ROTORS.
RATED POWER ABOUT 10 MW, 16000 rpm INPUT 8000 rpm OUTPUT
COMPONENTS TO BE TESTED AT 130% NOMINAL POWER, 110% SPEED
VARIOUS CONFIGURATION POSSIBLE SWITCHIN FRONT MULTIPLIERS.
UNIT DELIVERED AS TURN KEY INSTALLATION, COMPLETE OF CONTROL SYSTEM AND ON BOARD
SENSORS.
16000 rpm
8000 rpm
SCHEMATIC POWER
FLOW DIAGRAM AND
THE TEST MACHINE IN
ITS FINAL
INSTALLATION
PLANETARY LOAD SYSTEM
APPLIED TORQUE
MAIN MOTOR LINE
LINE TO COMBINER
DETAIL OF PLANETARY LOAD SYSTEM TORQUE APPLICATION. THIS SYSTEM IS USED ON ALL
OUR MECHANICAL LOOP TEST BENCHES.
THIS IS A SIMPLE, RELIABLE AND EFFECTIVE LOAD APPLICATION SYSTEM.
THE SYSTEM IS BASED ON STANDARD, RELIABLE INDUSTRIAL COMPONENTS TO DECREASE
COSTS AND INCREASE MAINTENEABILITY.
THIS SYSTEM ALLOWS OPERATION WITH BOT LINEAR INPUT CONTROL AND CLOSED LOOP
CONTROL.
TURN KEY TEST BENCH CENIT-2 FOR THE POLITECNICO DI
MILANO.
FATIGUE TEST OF GEARS MATERIAL AT VARIABLE
TEMPERATURE –GEARS ARE TESTED TO 107 LUFE CYCLE TO
VERIFY PITTING AND MICROPITTING EFFECTS. TEMPERATURE
CAN BE SET FROM 30° TO 120° C, ROTATIONAL SPEED 3000
rpm. FULL AUTOMATIC SETTING – CAN WORK 24/7 AND
SIMULATE LOAD CYCLES.
TORQUE APPLIED BY HYDRAULIC ACTUATOR
200-1000 Nm WITH 0,1% ERROR EOS
M
P
ROTATING DISTRIBUTOR
APPLIES UP TO
100 bar IN THE INPUT
SHAFT
THE DIFFERENTIAL PRESSURE
APPLIED IN THE CHAMBERS OF THE
ACTUATOR
GENERATES THE TORQUE DIRECTLY
INSIDE THE LOOP. THE ELECTRIC
MOTOR ONLY SUPPLIES POWER
NEEDED FOR KEEPING THE SYSTEM
IN ROTATION
CAT TEST BENCHES CONTROL SSTEMS ARE DESIGNED INTERNALLY. PROGRAMMING AND
CONSTRUCTION ARE OUTSOURCED UNDER A STRICT SUPERVISION. FINAL TEST AND
INTEGRATIONS ARE MADE IN CAT WORKSHOP OR UNDER CAT SUPERVISION
IN THE DESIGN PHASE, PARTICULAR CARE IS
GIVEN TO AUTOMATED ALARM HANDLING
AND DATA PROCESSING.
ACTUAL DATA SAMPLING DIRECTLY FROM
CONTROL SYSTEM IS 40kHz MAX . CONTROL
LOOP FOR A MEDIUM TO COMPLEX SYSTEM
LIKE NICETRIP PCS IS ABOUT 2ms (0,02s)
THIS GUARANTEES THE FINE TUNING
CAPABILITY FOR LOAD OR TORQUE
TRACKING/FOLLOWING SYSTEM
FOR MORE IN-DEPT ANALYSIS
REQUIREMENTS, DAQ SYSTEMS OR ORDER
ANALYSIS SYSTEM CAN BE INTEGRATED IN
THE CONTROL SYSTEM. OPERATOR
INTERFACE CAN BE ADAPTED TO THE TEST
REQUIREMENTS AND OPERATOR LEVEL
CAPABILITIES
 SYSTEM REQUIREMENTS
 DESIGN PROCESS
 CONTROL STRATEGY
 ARCHITECTURE DEFINITION
 LOGIC BLOCK DIAGRAM

RISK ASSESSMENT AND CONTAINMENT
STRATEGY

HARDWARE DEFINITION

RISK ASSESSMENT AND
CONTAINMENT STRATEGY

HARDWARE LAYOUT


SOFTWARE AND HARDWARE
INTEGRATION
OPERATIONAL TEST PHASE
(STATIC AND DYNAMIC)
NO

DEBUGGING
YES
RISK ASSESSMENT GRID SAMPLE
CATASTROPHIC FAILURE: TEST CANNOT BE RESUMED; POTENTIAL LIFE
DANGER FOR OPERATORS
ROOT CAUSE ANALYSIS REQUIRED
MAJOR FAILURE. DAMAGE TO TEST ITEM OR EQUIPMENT: TEST CAN BE
RESUMED BUT A LONG REPAIR TIME IS ADVANCED (MORE THAN 5 DAYS)
ROOT CAUSE ANALYSIS REQUIRED
MINOR FAILURE. DAMAGE CAN BE REPAIRED IN LESS THAN 1 DAY.
REPORT ON FAILURE ACCLUDED TO TEST REPORT
ALARM STOP. NO DAMAGE TO TEST ITEM AND EQUIPMENT. MINIMAL
OPERATIONS REQUIRED. PROBLEM SOLVED IN SOME HOURS.
REPORT ON FAILURE ACCLUDED TO TEST REPORT
MINOR ALARM STOP: TEST CAN BE RESUMED IN LESS THAN 15 MINUTES
REPORT ON FAILURE ACCLUDED TO TEST REPORT
THE LOGIC DIAGRAM IS THE BASE OF THE CONTROL SOFTWARE FROM WHICH WE CAN
• DEFINE CYCLIC OPERATION
• SET PARAMETERS
• PROGRAM ALARMS FOLLOWING THE MASTER ALARM TABLE
• VERIFY SPERIMENTALLY THE WORKING PRINCIPLES
• VERIFY COMMAND INTERFERENCE
• COMMISSION THE SYSTEM
THE TEST PHASE OF ACTUATORS AND SENSORS IS MANDATORY FOR EACH SYSTEM.
EVERYTHING IS CHECKED IN THE WORKSHOP BEFORE INSTALLATIONS TO BE SURE OF THE
CORRECT BEHAVIOUR AND TO VERIFY CONTROL LOOPS BEFRORE ACTUAL TESTING WHENEVER
POSSIBLE
SAMPLE QUESTIONS TO ANSWER
1. WHICH DATA SAMPLE RATE IS REQUIRED?
2. A SPECIFIC SOFTWARE IS REQUIRED FOR THE
ANALYSIS?
3. REAL TIME ANALYSIS IS USEFUL?
4. THE DAQ CAN BE INTEGRATED FOR ALARM
HANDLING?
5. IS BETTER TO HAVE ONE SYSTEM FOR ALL OR
SEVERAL SYNCHRONIZED UNITS?
6. CAN WE WORK WITH DIGITAL SIGNALS?
7. OPERATOR TRAINING LEVEL?
SPECIFIC ORDER ANALYSIS SOFTWARE CAN BE
INTEGRATED IN THE DESIGN
• EXTREMELY POWERFUL
• HIGH END CAPABILITIES
• SCALABLE FROM 4 TO OVER 100 CHANNELS
• REQUIRES HIGHLY TRAINED PERSONNEL TO
SET AND OPERATE
FOR LOWER REQUIREMENTS DAQ CAN BE
INTEGRATED IN PLC PROGRAMMING (UP TO
4kHz SAMPLE RATE) USING SPECIFIC
HARDWARE
For Airbus Helicopter
Qualified ISO 9001:2011