大型飞行器多通道分布式全机结构试验加载与协同控制

Structural tests are indispensable for the development and certification of aircraft, to guarantee efficient and safe operation in service. Full-scale structural testing has become a compulsory part for the aircraft design and manufacture process. There is an increasing demand for the accomplishment of extensive test series, especially considering the fact that Chinese large commercial airplane is supposed to complete its first flight task next year. Challenges facing our aviation industry still exist even though the high-tech imported equipments are being used to perform all these tests. Structural testing is a time-consuming and energy-inefficient process. In order to simplify system layout, improve reliability and efficiency without compromising test fidelity, a solution named as "Multi-channel Distributed Structural Loading Test System and Control on Full-scale Airframe of Jumbo Aircraft" is proposed in this application. Implementations of Power-by-Wire integrated actuation technology and real-time industrial bus make it possible to build up a brand new highly efficient loading system for aircraft structure testing. Focus on two fundamental scientific problems, "Design of high dynamic synchronization control for multi-channel loading system", and "Research on the design and energy management of Power-by-Wire integrated actuator", key technologies such as multi-channel controller design for accelerated aircraft structural fatigue test, cross-coupling compensation, digital PBW integrated actuation, central control for distributed network, etc., are expected to be thoroughly studied to meet the pressing needs of Chinese aviation industry.

飞行器结构是关系到飞行安全的最核心组成部分。全机结构试验作为一种规范，已列为研制生产飞机必须进行的试验。我国大飞机明年首飞，大型运输机即将开始疲劳测试，一大批大型飞行器的研制任务紧迫。近几年国内全机结构试验行业即使全部采用进口设备也面临四大挑战：急需大幅缩短疲劳试验时间提高效率、急需减少工作量、急需提高节能水平、急需提高试验系统可靠性安全性。因此针对以上瓶颈问题，本申请提出研究"大型飞行器多通道分布式全机结构试验加载与协同控制"，提出探索全新的高效高安全试验体系。通过功率电传一体化加载力作动系统和实时数字总线网络构建多通道分布式全机加载系统，突破"极多通道高动态协同加载控制理论"和"功率电传一体化加载力作动创成原理与能量调控"两个科学问题。解决多通道协同疲劳加速、结构耦合谐振、数字电传节能加载作动、核心分布式控制系统等关键技术，大大提高试验效率和试验水平，满足国家一系列重大型号的急迫需求。

飞机全机结构加载试验是检验飞机结构安全的最核心的手段，而国内全机结构试验行业即使全部采用进口设备也面临四大挑战：急需大幅缩短疲劳试验时间提高效率、急需减少工作量、急需提高节能水平、急需提高试验系统可靠性安全性。因此，为解决以上的瓶颈问题，本项目原创提出了“大型飞行器多通道分布式全机结构试验与协同控制”，主要针对功率电传一体化加载力作动创成原理与极多通道高动态协同加载控制两个科学问题进行了研究。.取得了以下重要成果：①构建了基于功率电传一体化力作动与实时数字总线网络的新型分布式全机结构加载试验系统体系架构；②原创提出了负载敏感的定速电机定量泵阀控一体化作动器、主动负载敏感的电动静液作动器、能量调控型电动静液作动器等功率电传作动器新原理：针对静力加载试验中节流损失高的问题，提出了负载敏感的定速电机定量泵阀控一体化力作动新原理，将加载效率提高了1.75倍；针对疲劳加载试验中恒力加载与顺载加载两种工况下电动静液作动器电机发热大的问题，提出了主动负载敏感的电动静液作动器与能量调控型电动静液作动器两种新原理，经过样机试验测试，电机发热分别能够降低23.7%和42%；提出了非对称缸的电动静液作动器新原理，以解决单出杆液压缸左右容腔不对称导致电动静液作动器加载性能下降的问题。③提出了新型的集中质量建模方法，分析了多通道强耦合机理，创新性的提出了运动同步复合解耦控制算法，搭建了国内第一台专用于多通道结构加载耦合测试的试验台，验证了该算法能够将疲劳加载频率从现有0.1-0.3Hz提高一倍以上，达到0.6Hz，极大的提高了疲劳加载效率。.本项目构建了多通道分布式全机结构加载试验新体系，突破了功率电传一体化节能加载力作动、核心分布式控制系统等关键问题，解决了多通道、高动态下结构耦合谐振降低加载效率的难点，大大提高了试验效率、降低了功率损耗，突破了国家重大需求的技术难题，部分技术已经开始应用，未来预期能够满足国家系列重大型号结构试验急需。