Structural design: The test bench should have a stable mechanical structure that can withstand the high-speed rotation and high-pressure airflow of the turbo compressor. Factors such as vibration and thermal expansion should be taken into account during design.
Material selection: Use high-strength, high-temperature resistant materials such as stainless steel and titanium alloy to ensure the stability of the test bench under high-pressure and high-temperature environments.
2. Sensor selection and installation
Pressure sensor: Installed at the inlet and outlet of the compressor to measure the intake pressure and exhaust pressure.
Temperature sensor: Installed at the inlet and outlet of the compressor to measure the intake temperature and exhaust temperature.
Flow meter: Used to measure the gas flow of the compressor. Common flow meters include thermal flow meters, turbine flow meters, etc.
Speed sensor: Used to measure the speed of the compressor. Usually a non-contact sensor such as a photoelectric sensor or a Hall sensor is used.
Torque sensor: Used to measure the torque of the compressor and installed on the drive shaft of the compressor.
3. Data acquisition and processing
Data acquisition system: Use high-precision data acquisition cards and software to collect sensor data in real time.
Signal processing: Filter and amplify the collected signals to eliminate noise and interference.
Data storage: Store the processed data in the database for subsequent analysis and report generation.
4. Test process
Pre-test operation: Before the formal test, perform a pre-test operation to check whether the sensor, data acquisition system, etc. are working properly.
Steady-state test: When the compressor is running stably, collect data such as pressure, temperature, flow, speed and torque.
Dynamic test: Simulate operation under different working conditions, such as variable load and variable speed, and collect dynamic response data.
5. Efficiency calculation
Compressor efficiency: Calculate the adiabatic efficiency, multivariable efficiency and isothermal efficiency of the compressor based on the collected pressure, temperature, flow and other data.
Mechanical efficiency: Calculate the mechanical efficiency of the compressor through torque and speed data.
Power calculation: Calculate the input power and output power of the compressor based on torque and speed.
6. Error analysis and correction
System error: Analyze the errors of sensors and data acquisition systems and make corrections.
Environmental factors: Consider the impact of ambient temperature, humidity and other factors on the test results and make corrections.
7. Test report
Data analysis: Analyze the test data in detail and draw performance curves, such as efficiency curves, power curves, etc.
Report generation: Generate a detailed test report, including test conditions, test results, performance analysis, error analysis, etc.
8. Maintenance and calibration
Regular maintenance: Regularly maintain the test bench and check the working status of sensors, data acquisition systems, etc.
Calibration: Regularly calibrate the sensor to ensure measurement accuracy.
Through the above steps, the customized turbo compressor test bench can achieve accurate measurement of mechanical efficiency and provide a reliable basis for the design optimization and performance improvement of turbo compressors.
