Accepted Manuscript Control-oriented modeling and real-time simulation method for a dual-mode scramjet combustor Jicheng Ma, Juntao Chang, Junlong Zhang, Wen Bao, Daren Yu PII:
S0094-5765(18)31018-X
DOI:
10.1016/j.actaastro.2018.10.002
Reference:
AA 7123
To appear in:
Acta Astronautica
Received Date: 15 June 2018 Revised Date:
18 August 2018
Accepted Date: 1 October 2018
Please cite this article as: J. Ma, J. Chang, J. Zhang, W. Bao, D. Yu, Control-oriented modeling and real-time simulation method for a dual-mode scramjet combustor, Acta Astronautica (2018), doi: https:// doi.org/10.1016/j.actaastro.2018.10.002. This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain.
ACCEPTED MANUSCRIPT 1 2 3 4
Control-Oriented Modeling and Real-Time Simulation Method for a Dual-Mode Scramjet Combustor Jicheng Ma1, Juntao Chang2*, Junlong Zhang3, Wen Bao4, Daren Yu5 Harbin Institute of Technology, 150001 Heilongjiang, People’s Republic of China Abstract: The control-oriented modeling and real-time simulation method for a dual-mode scramjet
6
combustor has been conducted in this paper. The 1-D unsteady model coupled with isolator shock train
7
model and oblique shock wave modification can treat variable area, fuel addition, combustion heat
8
release, variable specific heat, inflow air vitiation component, wall friction and mixing efficiency.
9
Combustion is simplified into mass and heat addition process. So this paper discusses heat release
10
distribution obtaining method which can be applied in scramjet combustor 1-D flowfield simulation in
11
detail. It is fit for certain scramjet combustor configuration and acceptable over a wide range of inflow
12
conditions. By mixed programming of C and Matlab, the code of model solving is capsuled into
13
S-Function which can be used in SIMULINK. The control-oriented model is built on SIMULINK
14
platform. When the model runs in a single-core 3.6GHz Intel Core i7-4790 processor, computation
15
time-consuming is found to require 5-10ms within a control period. The computing speed indicates
16
very promising, because model is compact enough to run in real time, and it can be used as an
17
embedded model in control system research. This model can also be used to analyze unsteady and
18
steady flowfield characteristic. The safety boundary codetermined by unstart and over-temperature is
19
conducted using this model.
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Keywords: Control-oriented modeling; Real-time simulation; One-dimensional model; Dual-mode
22
combustor; Heat release distribution
24 25 26 27 28 29
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1 PhD Candidate, School of Energy Science and Engineering,
[email protected] 2 Professor, Academy of Fundamental and Interdisciplinary Sciences,
[email protected]. 3 PhD Candidate, School of Energy Science and Engineering,
[email protected]. 4 Professor, School of Energy Science and Engineering,
[email protected]. 5 Professor, School of Energy Science and Engineering,
[email protected]. 1
ACCEPTED MANUSCRIPT Nomenclature
30 =
cross-sectional area
x
=
axes coordinate
Cw
=
wetted perimeter
ρ
=
density
Et
=
total energy
=
combustion efficiency
f
=
friction coefficient
ϕ
=
fuel equivalence ratio
H
=
isolator height
θ
=
momentum thickness
Hs
=
total enthalpy
Ma =
Mach number
Subscripts
=
fuel addition ratio
comb =
combustion
p
=
static pressure
i
=
mesh serial number
Re
=
Reynold number
s
=
t
=
time
w
=
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A
strut
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wall
Ttotal =
total temperature
u
=
velocity
=
fuel injection velocity along x axis
Supscripts n
=
time step serial number
1. Introduction
31
Scramjet is regarded as an ideal propulsion device during hypersonic flight within the atmosphere,
33
which owns many advantages such as long range, high specific impulse, high Mach cruise and direct
34
access to Earth orbit [1],[2]. Due to broad application prospects in space transportation and weapon
35
equipment, it aroused much interest in many countries. From starting acceleration, cruise to terminal
36
guidance, scramjet works over a broad range of hypersonic flight conditions. Hence, control system
37
must rapidly adjust working condition to match complex flight task. For hardware-in-loop simulation
38
system [3], scramjet combustor working process is replaced by control-oriented model, and working
39
states estimation does not rely on real experiment measurement directly. Correspondingly, combustor
40
model used for control algorithm evaluation is needed to estimate quickly performances such as thrust
41
to simulate the situation where flight Mach number and angle of attack change or any perturbations to
42
the design trajectory occurs. Control-oriented model of combustor requires a reduced-order model
43
with about 10ms of computational time. Based on above mentioned reasons, control-oriented
44
modeling and real-time simulation method for a dual-mode scramjet combustor are needed to develop
45
and estimate control system.
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A control-oriented model requires advantages both relatively small amount of computational time
47
and relatively accurate solution for the combustor flow. Multi-dimensional models can provide
48
detailed flowfield structure in scramjet combustor. The kinetic model and chemistry, which are the 2
ACCEPTED MANUSCRIPT most typical for the combustion mode in the engine, were applied in numerical simulation and show
50
satisfactory result [4]. Huang [5]-[9] developed many meaningful investigations about shock wave
51
transition, combustion and ram-scram transition mechanism in scramjet. They have instructive
52
significances to the scramjet numerical simulation. But computing burden of multi-dimensional
53
models is huge so that they cannot run in real time to meet the requirements of control design and
54
evaluation. A large number of table look-ups were also used to reduce execution time [10],[11]. It
55
means that run conditions were restricted between the bounds of pretabulated cases. Solving model
56
was reduced into an interpolation or a regression scheme. When pretabulated cases are sufficient, it
57
may have an acceptable precision for interpolation. But there exist uncertainties for extrapolation.
58
Since the conservation laws are not solved directly, it’s in the absence of physics content and accuracy.
59
Furthermore, there is phenomenon called mode transition accompanied with sudden change such as
60
thrust during working process of combustor. When fuel equivalence ratio changes from small to large
61
or from large to small, there exists different mode transition fuel equivalence ratio. Meanwhile angle
62
of attack in same flight Mach may arouse mode transition in certain case. A great deal of simulation
63
cases are needed if mode transition wants to be captured exactly. In addition, control research not only
64
needs thrust, but also pays more attention to changes of unsteady flowfield. As a consequence,
65
control-oriented model relies heavily on zero-or-one dimensional simulation. In previous works,
66
Lumped Parameter Method were applied to analysis overall performance of engine [12]-[14]. This
67
simple method can realize fast simulation. But it is possible that control system obtains unreliable
68
information so that scramjet combustor cannot fulfill a given control task. To solve this problem, a
69
method of distributed parameter control for dual-model scramjet combustor was proposed [15],[16].
70
One-dimensional (1-D) model can reflect distributed parameter characteristics of scramjet combustor
71
flowfield. It has been developed to support hypersonic vehicle design studies, flight dynamics, control
72
system design and analysis because of its moderate precision [17],[18].
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At present, there are two kinds of 1-D scramjet combustor model, which is based on Partial
74
Differential Equations (PDEs) or Ordinary Differential Equations (ODEs). 1-D scramjet combustor
75
model based on PDEs was presented by Bussing [19] in 1980’s. The Navier-Stokes equations were
76
reduced to a set of one dimensional unsteady inviscid flow equations, namely Euler equations. The
77
governing equations were solved by MacCormack method. After that, this method was improved to
78
handle the effects of heat release source terms addition, area variation, friction, mass addition, heat
79
transfer to combustor wall, and variable specific heat, and it was used to analyze unsteady process and
80
supersonic combustor performance [20],[21]. Evaporation of liquid fuels and the oblique shock train in
81
the isolator were taken consideration into 1-D unsteady model so that the model could simulate various
82
fuels and show dual-mode characteristic [22]. Fewer models based on PDEs were used in scramjet
83
combustor because solving model needs complex finite-difference method such as MacCormack or the
84
advection upstream splitting method (AUSM). 1-D scramjet combustor model based on ODEs can be
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ACCEPTED MANUSCRIPT referred in literature [23]. This method has been widely applied in performance analysis, combustor
86
initial design and control research. Previous models made utmost efforts to develop the accuracy of
87
simulation by taking consideration of the effects of fuel injection, mixing, chemical production rates,
88
heat transfer, and viscous losses [24]-[26]. The computation time-consuming of engine flowfield is on
89
the order of 1-2s. This model has been applied to compute the sensitivity of the thrust to the vehicle
90
angle of attack, as well as the poles and zeros of the transfer functions that relate control inputs of fuel
91
setting and elevator [27],[28]. In addition, many other researchers made considerable efforts to develop
92
fast 1-D simulations that can run in short time periods [29],[30] and evaluate dual-mode characteristic
93
[31]. However, solving ODEs process exists a mathematical singularity in the equations when the flow
94
velocity approaches the speed of sound [32],[33]. This singularity problem becomes significantly
95
important when considering subsonic combustion cases. Furthermore, dealing with combustion
96
chemistry in 1-D model is a key issue both in 1-D model based on PDEs and ODEs. Firstly, there exists
97
stiffness problem during solving chemical governing equations due to time scales mismatching
98
between chemistry and flowing. Thus, the solution procedure is computationally expensive. Meanwhile
99
the governing equations of fluid flow with detailed chemistry may generate a highly nonlinear problem
100
during integrating these equations. Secondly, even though the detailed chemistry mechanism is
101
accounted, the accuracy of computation would not change substantially. Lastly, if combustion is
102
simplified into combination of heat release and mass addition, there is a problem in heat release
103
distribution law and its universality over a wide range of conditions. It has apparent impact on
104
computation accuracy of flowfield. Moreover, heat release distribution has not yet coincident empirical
105
modification method and relies heavily on experimental data.
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In the field of scramjet combustor, related researchers have also developed many reduced-order
107
models, but the computation time-consuming is mostly measured on the order of seconds. It is obvious
108
that these models cannot accomplish real-time optimization of scramjet combustor control system. By
109
pre-setting controller parameters to tolerate all kinds of uncertainty and perturbations, performance of
110
scramjet combustor is not optimal. As a whole, control research is in sore need of 1-D control-oriented
111
model which has advantages both relatively small amount of computational time and relatively
112
accurate solution for the combustor flow. Hence, this paper proposes control-oriented modeling and
113
real-time simulation method for a dual-mode scramjet combustor. In this paper, a 1-D unsteady model
114
based on PDEs is discussed in detail. This method can conduct transient analysis without assumption of
115
the shock location. Flowfield characteristics distributions are calculated at each time step of a
116
simulation, instead of being stored in look-up tables. Then flowfield characteristics in this time step are
117
given to next time step initial state of the combustor. The model coupled with isolator shock train
118
model and oblique shock wave modification can treat variable area, fuel addition, variable specific heat,
119
inflow air vitiation, wall friction, combustion and mixing efficiency. To shorten computation
120
time-consuming, combustion is simplified into mass and heat addition process without the process of
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spraying and mixing. Meanwhile, mixed programming of C and Matlab is applied. Using these
122
methods mentioned above, this model can meet the requirement of real-time simulation. Additionally,
123
model presented in this paper can also been used to analyze unsteady and steady flowfield
124
characteristic. The safety boundary decided by unstart and over-temperature is conducted in the end of
125
this paper.
127
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2. One-dimensional modeling method
126
2.1. Governing equations and numerical solution method
Flow in a duct having a slowly varying cross-section where the duct height is small compared to the
129
radius of curvature of the axis of the duct is termed a quasi-one-dimensional flow [34]. A truly 1-D
130
unsteady flow is one where the flow properties depend only on space coordinate x and time t. The
131
pathlines of the fluid particles are straight lines, and the flow properties are uniform across all surfaces
132
perpendicular to the main flow direction. The governing equations for unsteady 1-D flow are derived in
133
this section. If the effects of work and body forces are neglected, the flow equations are inviscid
134
adiabatic, so an equivalent wall friction model has been incorporated into the 1-D model to give more
135
realistic drag estimates. In that case, the flow area is only a function of x and t. Based on unsteady 1-D
136
Euler equations, the model accounted for variable area, fuel addition, combustion heat release, variable
137
specific heat, inflow air vitiation component, wall friction and mixing efficiency. Mixture gas
138
parameters can be obtained by mass-weighted average. Constant-pressure specific heat Cp and enthalpy
139
of single component are function of temperature that can be referred at NIST. Governing equations can
140
be expressed as follows:
141 142
=
In equation (1):
144
,
,
=
We want to evolve
/
!"# !
,
+
!$ !
;
−
&'(
,
= +
(1)
;
) ∙ +, +
!"# !
,- ∙
from time 0 = 0 / to the new value
/12
∆0 = 0 /12 −0 / . The splitting can be derived as follows [35]:
∙
!"# !
. ;
at 0 = 0 /12 in a time step
148
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=
,
+
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149
For solving the advection (2), AUSM flux vector splitting is applied for the approximation of the
146 147
150 151
152
+
!
5, 0 / =
!
= 8 /12
=4 /
6 ⇒ 8 /12
9⇒
(2)
/12
(3)
convective flux function. Flux in the duct with varied area can be expressed as follows: :12⁄
=
:12⁄
<
+
=
:12⁄
+ >:1 <
0 0
1 = + >:12 < :
0 0
=
:12
(4)
For source terms that are independent of time or involve spatial derivatives, one can use the Euler 5
ACCEPTED MANUSCRIPT 153
method resulting from evaluating the integral at the old time. The Euler method is explicit and
154
first-order accurate. For solving equation (3), it can be expressed as follows: /12 = 8 /12 + ∆0 ∙ 8 /12
155 156 157
Where ∆0 = 0 /12 −0 / is the time step and
/
approximately equals
2.2. Normal shock wave treatment and isolator train model
(5)
0/ .
In 1-D model, there are substantial limitations, such as no oblique shock wave but normal shock
159
wave, which is unreasonable. Therefore, proper modification is necessary. After model is solved, if
160
back-to-front static pressure ratio along axial detected is greater than a specified value, it is thought that
161
there exists normal shock wave. Then the calculation results are modified according to the law of
162
quadratic function as shown in Fig. 1. By this modification method, the model can simulate transition
163
between ram-mode and scram-mode operation which previous models did not include.
p/MPa
0.3
0.25
0.2 0.25
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Calculation Modification
0.35
164
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0.3
0.35
0.4
0.45
x/m
Fig. 1. Pressure modification schematic at normal shock wave
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As a performance adjustable bumper and engine regulating actuator, isolator can expand scramjet
167
combustor operating domain. Isolator shock train has obvious and complex non-1-D characteristic. To
168
catch this special phenomenon accurately in 1-D model, Billig’s empirical method [36] is used in this
169
work. Firstly, selecting isolator exit pressure as backpressure
170
A BCD( E2 IFG@H
171
Pressure distribution is modified from shock train leading edge point to isolator exit. In the formula, L
172
is shock train length in the isolator, if it exceeds isolator length, unstart will generate and computation
173
is terminated; Mai is isolator inlet Mach number; Reθ is Reynold number which based on inlet
174
momentum thickness, generally it is 10000; H is isolator height; θ is inlet boundary layer momentum
175
thickness; θ/H is equal to 0.02 generally[1],[37]. It is just a method in 1-D simulation when
176
experimental data is lacked. Precision will fit for control research as long as they are defined as
177
relatively reasonable values..
178
2.3. Mixed programming method of C and Matlab
= M50
OP OD
− 1. + 170
OP OD
and then equation
− 1. S is applied to solve isolator shock train length.
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S-function is system function in Simulink which is used to describe module macro function. When
180
S-function modules provided by Simulink default don’t meet the requirements, users can make
181
modules by themselves to realize user-defined algorithm and desired action. S-function can be 6
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programmed in several kinds of languages, including M, FORTRAN and C. In reference [38], a
183
separate FORTRAN code interfaces with MATLAB as a MEX file in the research of reacting flows
184
with detailed chemistry and transport. C language has flexibility in programming, enormous computation function and a faster running
186
speed. Similarly, S-function can also be programmed into C Mex file using C language. Compared
187
with running interpreted S-function which is programmed using M language, MATLAB interpreter is
188
not called repeatedly during simulation, so the method has obvious advantages in runtime and
189
calculation efficiency. In addition, S-function can be applied to hardware-in-loop simulation platform
190
conveniently. Hence, this paper presents that the model is solved using C programming language, and
191
then the code is encapsulated into S-function.
193
According to program structure sequence, C Mex S-function file is composed of such sections as
SC
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follows [39]:
(1) The S-function begins with #define statements for the S-function name and level;
195
(2) Header files include parts of C Mex S-function core data structure and other library files.
196
Moreover it also includes other header files as needed. For example, math.h is included if code goes on
197
arithmetical operation utilizing C standard library; fixedpoint.h is included if code uses built-in
198
fixedpoint data type in SIMULINK. Every C Mex S-function has its own simstruct data type plant to
199
ensure each S-function internal data independent.
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201
variable TRUE/FALSE. By these macros, C Mex S-function module can obtain the value of each
202
control in parameter dialog conveniently, so that it is applied in each submethod.
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(4) After that, in C Mex S-function each submethod is defined, such as Initialize, InitializeSampleTimes, updating state variables, Output, mdlRTW, terminate and so on. (5) At the end, S-function must include necessary source and header files according using condition,
206
so that it connects SIMULINK or SIMULINK Coder products. If this section is ignored, the whole
207
compilation will fail.
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After code structure is built as listed above, through a special compilation process, code can be
209
compiled into machine language files, such as mexw32 or mexw64 file. Only after code is compiled
210
into executable file can it be called by SIMULINK. Code using compiled language directly instead of
211
compiling repeatedly can ensure high efficiency operation. This is also the reason why users are
212
recommended the use of C Mex S-function when fast simulation is desired.
213
3. Heat release distribution obtaining and real-time simulation
214
3.1. Heat release distribution obtaining
215
3.1.1. Experimental setup descriptions
216
To validate the accuracy of scramjet combustor 1-D control-oriented model numerical results, parts
7
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Technology in China [40],[42]. In the scramjet combustor, there are a constant width of 100mm and
219
single side divergence lower wall. The total length of the combustor is 1.620m with a total divergent
220
ratio of 2.5. Some pressure sensors are distributed on the center line of side wall. Schematic
221
configuration of combustor is shown in Fig. 2. The detailed geometry of strut can be found in reference
222
[43]. Strut fuel injector employed as the first stage fuel injector is located at x=0.36m. The second stage
223
fuel injected from wall fuel injector is located at x=1.08m. Hydrocarbon fuel at room temperature
224
(about 300K) is injected in the direction normal to the airflow direction, with fuel total equivalence
225
ratio ranging from 0.1 to 1. The hydrocarbon fuel used in experiments is China No.3 aviation kerosene.
226
In computation, kerosene surrogate molecular formula is C10H22, whose heating value of combustion is
227
42.5MJ/Kg. PJ ignitor
100
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Pressure sensor
84
60
Wall fuel injector
100
Strut fuel injector O2
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of experiments has been conducted at the supersonic combustion research facility of Harbin Institute of
40
217
260
400
229 230
100
320
420
100
Fig. 2. Schematic configuration of combustor (mm) 3.1.2. Heat release distribution obtaining method
Modifications and simplifications must be made for the mathematical model to allow the application
232
of a given tasks [44]. When detailed chemistry mechanism is accounted, accuracy of code can be
233
developed in a degree, but computation time-consuming is huge. In the model presented in this paper,
234
combustion process is simplified into combination of mass and heat addition. In calculation, heat
235
addition process can be described as heat release distribution function. By tailoring the heat release
236
profile, combustion operation can be modified to meet desired requirements. In 1-D model presented
237
by Jiang [45], mixing between air and fuel was taken into account, and fuel addition ratio along axial
238
direction was described using Rayleigh probability density method. Heat release was associated with
239
fuel mass distribution, so they had the same distribution law. Zhang [46] summarized existing
240
experimental results where OH spontaneous radiation plane images were observed in combustor when
241
fuel equivalence ratio was low, presented 1-D heat release distribution peicewise linear fitting model.
242
But this model can only be used in specific combustor configuration and fuel component. For
243
multi-stage injection and hydrocarbon fuel, some corresponding experiments were needed to analyze
244
image characteristic and adjust model parameters. Furthermore, this model is only fit for high speed
245
inflow condition and ramjet mode. In addition, parabolic fuel distribution and exponent mixing
246
distribution were also adopted in some literatures [47],[48].
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The above mentioned studies about the heat release distribution function mainly rely on existing
248
experimental data or specific parameter setup in their own model. However, it is not known if the heat 8
ACCEPTED MANUSCRIPT release function is fit for different scramjet combustor configuration, different fuel, different injection
250
form and multiple inflow conditions. For the moment, researchers lack unified, normative description
251
method and measurement means with regard to exploration and description of heat release distribution.
252
Hence, this paper presents a method that can be applied in scramjet combustor 1-D flowfield
253
simulation. Using this method and utilizing several existing experimental data, the heat release
254
distribution which is fit for certain scramjet combustor configuration and is acceptable over a wide
255
range of inflow conditions can be found. Heat release distribution modification and optimization flow
256
chart is shown in Fig. 3. Detailed procedures are listed from step 1 to 5 as follows:
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Step 1:
258
In the supersonic combustion research facility introduced in Section 3.1.1, cold flow experiments
259
were conducted for the scramjet combustor, and isolator inflow conditions, including total temperature,
260
static pressure, Mach number, and inflow air vitiation component, were measured. They are listed in
261
case 1, case2, case 3 and case 4 as shown in Table 1. In computation, boundary conditions are same as
262
Table 1. Wall is treated as adiabatic surface. Then density, constant-pressure specific heat, specific heat
263
ratio and other corresponding parameters can be obtained.
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Fig. 3. Heat release distribution modification and optimization flow chart
266
Table 1 Isolator incoming flow conditions in experiments Mole fractions ratio O ∶ N ∶ H O ∶ CO
Y + Y, allocation proportion
FZ[K
I
Case
Ma
Ttotal (K)
p (MPa)
1
2.0
965
0.153
1.000:3.190:0.333:0.238
30%+70%
√\1757.5
2
2.5
1027
0.089
1.000:3.143:0.381:0.238
48%+52%
1837.5
3
2.7
1480
0.059
1.000:2.810:0.571:0.381
65%+35%
1780.0
4
2.7
1865
0.063
1.000:2.657:0.662:0.443
100%+0%
1711.3
9
(
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Step 2:
268
Combustion experiments in case 1 at ϕ=0.77, in case 2 at ϕ=1.0 and in case 3 at ϕ=1.0 separately
269
were conducted. Pressure distributions along flow direction were obtained. Fuel allocation proportion
270
injected from strut and side wall of combustor has been shown in Table 1. Step 3:
272
Two categories of heat release distribution function which are exponent and polynomial form are
273
selected as the examples in this method as follows:
274 ]
275
=
276
279
^
^
−5̅ + 25̅
(6)
8 2.2bcd ̅ e.f(g(h ∙ie.I(fj(k
2.lm2n ̅ 1c.d mnn
5̅ =
(7)
E opq
Arstu
(8)
^
is fuel consumption mass flow rate which reacts chemically;
is fuel total mass flow; x
SC
278
]
Where
=
is combustor position along axial; 5vwx is fuel injection position; Lcomb is the length of combustion section.
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]
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271
Step 4:
281
Equation (6) is applied to 1-D model firstly. If calculation results appear relatively large deviations
282
comparing with experimental results, Lcomb should be modified and optimized until achieving the
283
satisfied results. Otherwise return to step 3 and select equation (7). In this paper, when upstream fuel
284
injection Lcomb is between 0.3m and 0.5m, downstream fuel injection Lcomb is 0.3m in heat release
285
distributions laws based on Equation (6), normalized wall pressure distributions along with axial
286
direction can meet the accuracy requirements against with experimental results. It can be seen in Fig. 4,
287
Fig. 5 and Fig. 6 separately. Based on pressure values, Table 2 gives root-mean-square deviation
288
between experimental and numerical results with different Lcomb. Root-mean-square deviation between
289
experimental and numerical results can be expressed as follows:
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∑D‰Š} yz = {
EP
ˆ
290 :
v ‹Œ• v w
/
(9)
: i Ži]v iw
is pressure value of simulation result in position i;
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291
(
D D D O#ot~•€•osp EO‚ƒ„‚…ot‚p• .†O‚ƒ„‚…ot‚p• ‡
is pressure value of
292
experiment in position i; n is total number of pressure sensors. As we can see from Table 2, in heat
293
release distribution law based on Equation (6), upstream fuel injection Lcomb equals to 0.4m is the most
294
appropriate. 4
L
comb
=0.30m
L
3.5
comb
=0.40m
L
comb
=0.50m
φ=0.77experiment
5.5
area
5
70%
30%
Lcomb=0.30m
Lcomb=0.40m
Lcomb=0.50m
48%
φ=1.0experiment
area
52%
4.5
2
3.5
area/m2
pressure ratio
4
2.5
area/m2
pressure ratio
3
3 2.5 2
1.5
1.5
1
0.01
0.5 0
0.004 1.6
0.2
0.4
0.6
0.8 x/m
1
1.2
1.4
0.01
1 0.5 0
10
0.2
0.4
0.6
0.8 x/m
1
1.2
1.4
0.004 1.6
ACCEPTED MANUSCRIPT Fig. 4. Experimental and numerical normalized wall pressure distributions in case 1 at ϕ=0.77 7
L
=0.30m
comb
L
6
comb
=0.40m
Fig. 5. Experimental and numerical normalized wall pressure distributions in case 2 at ϕ=1.0 L
comb
=0.50m
φ=1.0experiment
area
35%
65%
4
area/m2
pressure ratio
5
3 2 1 0 0
0.2
0.4
0.6
0.8 x/m
1
1.2
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0.01 0.004 1.6
1.4
Fig. 6. Experimental and numerical normalized wall pressure distributions in case 3 at ϕ=1.0
Table 2 Root-mean-square deviation between experimental and numerical results with different Lcomb Case Fuel equivalent ratio Lcomb=0.3m Lcomb=0.4m Lcomb=0.5m 1 0.77 12.8% 6.2% 6.4% 2
1.0
21.7%
3
1.0
13.9%
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10.1%
11.0%
8.7%
9.9%
Step 5:
297
Combustion experiments in case 3, 4 at different fuel equivalence ratio and fuel allocation proportion
298
separately were carried out for this scramjet combustor geometry. They are used to validate the
299
accuracy of upstream Lcomb=0.4m in other fuel equivalent ratios, fuel allocation proportion and inflow
300
conditions. Numerical results are compared with experimental results as shown in Fig. 7-Fig. 9. If
301
Lcomb=0.4m cannot meet the needed accuracy, return to step 4 and select different Lcomb until satisfied
302
value, otherwise return to step 3 and select equation (7).
3
1
0.2
0.4
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2
0.6
0.8 x/m
1
1.2
φ=1.00
φ=1.00experiment
area
100%
5 4 3 2
1.4
0.01
1
0.004 1.6
0 0
0.01 0.2
0.4
0.6
0.8 x/m
1
1.2
1.4
0.004 1.6
Fig. 8. Experimental and numerical normalized wall pressure distributions in case 4 at ϕ=0.74 and 1.0
φ=0.48experiment
φ=1.2 (40%+60%)
100% 40%
5
φ=1.2experiment
area
0% 60%
area/m2
4 pressure ratio
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φ=0.74experiment
6
Fig. 7. Experimental and numerical normalized wall pressure distributions in case 3 at ϕ=0.74 φ=0.48 (100%+0%)
φ=0.74
7
area/m2
4
0 0
8
area
35%
65%
5
pressure ratio
φ=0.74experiment
area/m2
φ=0.74
pressure ratio
6
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3
2
1
0 0
0.01 0.2
0.4
0.6
0.8 x/m
1
1.2
1.4
0.004 1.6
Fig. 9. Experimental and numerical normalized wall pressure distributions in case 3 at ϕ=0.48 and ϕ=1.2 303
Root-mean-square deviations between experimental and numerical result are listed in Table 3. It is 11
ACCEPTED MANUSCRIPT 304
obvious that the simulation results have a deviation within 10%, it can meet the need of control
305
research. Hence, numerical results of Lcomb=0.4 in other fuel equivalent ratios, fuel allocation
306
proportion and inflow conditions also meet the requirement of accuracy for 1-D simulation. With this,
307
heat release distribution is confirmed. Table 3 Root-mean-square deviation between experimental and numerical results in different case Case
Fuel equivalent ratio
Y + Y, fuel allocation
3
0.74
65%+35%
4
0.74
100%+0%
4
1.00
100%+0%
3
0.48
100%+0%
3
1.20
40%+60%
Root-mean-square deviation
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6.8%
5.9% 9.9% 8.9% 9.7%
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In addition, 3-D CFD simulation is necessary to show detailed flowfield structure and provides
310
comparison with 1-D simulation. In 3-D CFD simulation, accuracy of numerical scheme is
311
second-order upwind, which has two-order accuracy. The method of error estimation is from Smirnov
312
[49],[50]. The numerical calculation error estimates of 3-D simulation are shown in Table 4. The
313
40*50*800 grids are adopted as the calculation mesh at last. Computational fluid dynamics model
314
referred to reference [40]. Allowable error
Table 4 Numerical calculation error estimates of 3-D simulation Allowable Grid Time step Number of Accumulated number of time resolution size(µs) time steps error steps
5%
20*50*800
5%
40*50*800
5%
60*80*800
Reliability Rs=nmax/n
10
50000
1.330·10-4
1.413·105
2.8271
10
50000
2.363·10-5
4.479·106
89.583
10
50000
6.583·10-6
5.769·107
1153.9
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Fig. 10 shows static pressure contour in case 1 at ϕ=0.77. Meanwhile mass-weighted average of
317
static pressure is given in Fig. 11. 1-D simulation can have similar distribution along x-axis with 3-D
318
mass-weighted average of static pressure even though 1-D simulation cannot show detailed flowfield
319
structure. Nevertheless, 1-D simulation method is enough to control design and evaluation.
80000 Pa
1-D simulation
φ=0.77experiment
3-D CFD simulation
area
70%
30%
3 2.5
area/m2
Static pressure contour
4 3.5
pressure ratio
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2 1.5
400000 Pa
1 0.5 0
Fig. 10. Static pressure contour in case 1 at ϕ =0.77
0.01 0.2
0.4
0.6
0.8 x/m
1
1.2
1.4
0.004 1.6
Fig. 11. Comparison of mass-weighted average of static pressure distribution, 1-D simulation and experiment
320
This 1-D model has been proved valid within the experimental bounds by above analysis. During the
321
scramjet vehicle control, the angle of attack will result in different total and static pressure incoming 12
ACCEPTED MANUSCRIPT 322
flow condition. In order to validate 1-D model in such flight conditions which is outside the
323
experimental bounds, a 3-D CFD is performed. Bear in mind, for the situation where the vehicle works
324
in some an angle of attack, incoming flow will still embody uniform equivalent conditions in 1-D
325
simulation. In the previous study, some inlet designs and 3-D CFD simulations had been conducted
326
according to the reference[41]. Flight conditions have been listed in Table 5, and the equivalent
327
incoming flow conditions of combustor has been listed in Table 6. Table 5 Flight conditions of scramjet vehicle Angle of Altitude(km) Static pressure(Pa) attack(degree) 2 21 4729
Flight Mach 5
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329
Table 6 Equivalent incoming flow conditions of combustor Incoming Mach
Static pressure(MPa)
2.15
0.1459
Static temperature(K) 678.4
By 3-D CFD simulation, static pressure contour at Y + Y, =0.3+0.5 is shown in Fig. 12.
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Static temperature(K)
332
Meanwhile comparison of mass-weighted average of static pressure distribution and 1-D simulation is
333
given in Fig. 13. 1-D simulation can have similar distribution along x-axis with 3-D mass-weighted
334
average values. Hence, applicability of the 1-D simulation is checked for the situation where the
335
combustor works in angle of attack.
4
1-D simulation
3.5
3-D CFD simulation
area 63%
37%
Static pressure contour
100000 Pa
400000 Pa
area/m2
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pressure ratio
3
2.5 2 1.5 1 0.5 0
Fig. 12. Static pressure contour at Y + Y, =0.3+0.5
0.01 0.2
0.4
0.6
0.8 x/m
1
1.2
1.4
0.004 1.6
EP
Fig. 13. Comparison of mass-weighted average of static pressure distribution and 1-D simulation
It is necessary to validate 1-D model near unstart conditions. In case 1 at ϕ=0.77 and case 4 at ϕ=1.0,
337
the combustor works in such conditions. In case 1 at ϕ=0.77, comparison of 1-D, 3-D CFD simulation
338
and experiment have been conducted which are shown in Fig. 10 and Fig. 11. In case 4 at ϕ=1.0,
339
comparison of 1-D and experiment is shown in Fig. 8. By above researches, 1-D simulation shows
340
relatively satisfactory results near unstart conditions.
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As a whole, numerical results obtained from 1-D model are in good agreement with experimental
342
and 3-D CFD results no matter the incoming flow is in or outside experimental bounds. It does
343
successfully reproduce the pressure rise trend along flow direction. So by above steps, heat release
344
distribution function which is fit for 1-D model can be obtained aiming at this scramjet combustor
345
configuration over a wide range of inflow conditions.
346
3.2. Real-time simulation method and validation
347
The goal of developing a real-time simulation is not to replace high-fidelity and 13
ACCEPTED MANUSCRIPT high-spatial-resolution CFD solutions or real-world experiments. Instead, we seek to match numerical
349
and experimental results to an adequate degree of accuracy for control design and evaluation. The
350
computation time-consuming for full flow path kept on the order of 10ms can satisfy this goal.
351
Handling methods are listed as followed: (1) Combustion is simplified into mass and heat addition
352
process, heat release distribution function used in 1-D model can be obtained from Section 3.1.2. (2)
353
The relationships between inflow air specific heat at constant pressure, enthalpy and temperature are
354
tabulated to look up at all times in later calculations. (3) 1-D unsteady Euler equation is solved using C
355
programming language, then it is compiled into machine language in MATLAB. Lastly it is
356
encapsulated into S-function referred in Section 2.3. On SIMULINK platform, 1-D real-time model is
357
built, where memory module can return the results computed by S-function as flowfield initial value at
358
the next time step. In this way, the model can realize the maximum reduction of the computation
359
time-consuming. Flow chart of real-time model is shown in Fig. 14. (4) In premise that accuracy meets
360
the requirement of control on the whole, and calculation grid number should be minimized.
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362
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Fig. 14. Scramjet combustor flowfield 1-D real-time simulation block diagram
363
Based on the order of the numerical scheme accuracy and grids, the different grids, including 50, 70
364
and 140, are used as the error estimates of numerical calculation. In this paper, accuracy of numerical
365
scheme is one-order upwind, which has one-order accuracy. CFL is selected to 0.7. According to the
366
method for accumulation of errors estimations in the reference [49],[50], several simulations have been
367
conducted. The numerical calculation error estimates of 1-D simulations are shown in Table 7. Taking
368
into account of computation accuracy and time-consuming, grid total numbers are terminally selected
369
to 70.
370
This paper develops 1-D model which can run in real time. On hardware-in-loop simulation platform
371
the model is available as a module. Bear in mind that although some parameters in the model do not 14
ACCEPTED MANUSCRIPT 372
attempt to match the combustor flowfield parameters exactly, they should be functionally accurate. For
373
example, if this model is used to fuel control research, it is sufficient since fuel control is not
374
instantaneous but rather a stepwise process. This model can predict an averaged flowfield which is
375
useful for fuel calculations. Allowable error 5%
Table 7 Numerical calculation error estimates of 1-D simulations Grid Time step Number of Accumulated Allowable number resolution size(µs) time steps error of time steps 50
2.68
2500
4.000·10-4 -4
5%
70
1.34
5000
2.041·10
5%
140
0.67
10000
5.102·10-5
Reliability Rs=nmax/n
1.563·104
6.25
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4
12.01
9.604·105
96.04
6.003·10
To verify the real-time characteristic of this model, a large number of calculations in multiple flow
378
conditions should be conducted. In this paper, fuel supply signal is given as a slope and inflow
379
conditions is case 1, 2, 3 and 4. Computation conditions have been shown in Table 1. The real-time
380
model which runs in a single-core 3.6GHz Intel Core i7-4790 processor can acquire the full combustor
381
1-D flowfield structure. In control system research, one control period is generally 20ms. In Table 8, it
382
can be seen that all computation time-consuming are less than 10ms which is enough to satisfy on-line
383
control, so the control-oriented model can realize real-time simulation of scramjet combustor flowfield
384
at different fuel equivalence ratio over a wide range of inflow conditions.
385
Table 8 Computation time-consuming at different fuel equivalence ratio in each case Fuel equivalence ratio Computation time-consuming (ms) 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
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Case 2 Case 3 Case 4
387
6
5
6
5
6
7
7
—
—
6
6
5
6
5
6
6
6
7
5
7
6
6
7
6
7
7
6
7
8
8
8
7
7
7
8
9
9
9
9
4. Flowfield characteristic analysis
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1.0
4.1. Unsteady analysis
The process of this model being solved is based on time iteration, so it can show unsteady flowfield
389
characteristic. Steady flowfield at ϕ=0.2 are assigned to the whole flowfield as the initial values.
390
Numerical normalized wall pressure and Ma distributions at different time in case 1 at ϕ=0.77 are
391
shown in Fig. 15 and Fig. 16.
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Overall, the example calculation of heat addition from the initial flowfield (at t =0) to an established
393
diverging duct flowfield containing a shock is considered. In the rear part of the combustor, flowfield
394
tends to be stable choke state quickly and generates high backpressure. The flow can be only adjusted
395
via a shock moving forward. In this way, the flowfield tends to stable at a slower rate. The flowfield
396
and shock movement requires a time of 8ms to reach equilibrium. Note the theoretical times only give
397
an order of magnitude estimate of the overall time scales. From the example, we could see that the flow
398
is not stationary and shocks travel upstream to adjust inflow conditions. The 1-D model is able to 15
ACCEPTED MANUSCRIPT 399
simulate transient behavior of choked flow. 4
t=2ms
t=4ms
3.5
t=6ms
t=8ms
t=10ms
area
t=2ms
t=4ms
2
70%
30%
t=6ms
t=8ms
30%
t=10ms
area
70%
Ma
2
area/m2
1.5
area/m2
pressure ratio
3 2.5
1
1.5 1 0.5
0.2
0.4
0.6
0.8 x/m
1
1.2
1.4
0.004 1.6
0
Fig. 15. Numerical normalized wall pressure distributions at different time in case 1 at ϕ=0.77
0.2
0.4
RI PT
0 0
0.01
0.01
0.5
0.6
0.8 x/m
1
1.2
1.4
0.004 1.6
Fig. 16. Numerical Ma distributions at different time in case 1 at ϕ =0.77
Firstly, pressure field is analyzed. Fuel allocation proportion injected from the rear region is larger
401
than the front region in this case. Hence in the initial time, higher pressure peak firstly appears in the
402
rear region. In the same position Ma is equal to 0.4 that is far less than 1.0, so a strong thermal
403
chocking is inferred. In other word shock leads to pressure peak. Then the shock moves forward to
404
small area region, as a consequence of pressure lifting point moving forward which is located in front
405
of heat release region. Pressure peak value continue rising over time, simultaneously pressure lifting
406
point moves forward and is connected with the first stage heat release region. After t=6ms, flowfield
407
shows a slower growing trend. The backpressure at x=0.36m has risen less and maintain a high level
408
due to isolator. Ultimately, approximate constant pressure combustion is observed in the first stage heat
409
release region.
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Secondly, from the perspective of Mach number, the second stage combustion happening in constant
411
area region generates shock waves and leads to subsonic region. Nevertheless, in the initial flowfield
412
establishing process due to the second stage combustion has not yet established enough backpressure,
413
strong thermal choking impact is not obvious. So flowfield in the first stage combustion region which
414
happens in diverging area, transforms between subsonic and supersonic. After that, since the steady
415
stage of the flow relies on the propagation of information from the choking location in the combustor
416
up to the upstream supersonic inflow. Hence, subsonic region caused by the second stage combustion is
417
enlarged and combines with the first stage combustion region. Finally, the subsonic region generates
418
from the location of the isolator entrance, and the whole combustor is in a subsonic combustion mode.
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Eventually, flowfield is steady after t=8ms. Pressure rises from x=0.2m in the isolator due to
420
pre-combustion shock train. Then combustion heat release in the diverging region is balanced out by
421
area change, so pressure platform and Ma platform occurs. When heat release process is over, flowfield
422
is regarded as the simple flowing process of the high temperature and high pressure gas. In second
423
stage combustion region, flowfield velocity rises and pressure declines by the heating process, and heat
424
release process accelerates the flow towards the sonic limit till supersonic in nozzle region.
425
4.2. Steady analysis
426
Steady pressure distribution characteristics at different fuel equivalence ratio are analyzed below. Fig.
16
ACCEPTED MANUSCRIPT 17 and Fig. 18 show numerical normalized wall pressure and Ma steady distributions at different fuel
428
equivalent ratios in case 2. Pressure along with the flow direction rises from vicinity of isolator
429
entrance gradually as fuel equivalence ratio increases until to 1.0, at which scramjet combustor is still
430
not unstart and pressure reaches the peak in the first stage heat release region. Heat is added in the
431
diverging area regions and the constant area, leading to the appearance of thermal choking. The
432
position of heat addition has influence on the shock positions and heat addition causes the shock to
433
move forward to a region of smaller area. Fuel allocation proportions injected from the two stages are
434
approximately the same in this case. But in the rear region pressure peak and subsonic flowfield arise
435
when the whole fuel equivalence ratio is smaller. It is explained that constant area regions can contain
436
less combustion heat release than diverging area regions. φ=0.2
φ=0.5
φ=0.7
φ=0.85
48%
φ=1.0
3
area
52%
φ=0.0
2
φ=0.5
1.5
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Ma
2
area/m
pressure ratio
4 3
φ=0.2
φ=0.7
φ=0.85
48%
2.5
φ=1.0
area
52%
area/m2
φ=0.0
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1
1
0.5
0.01
0 0
0.2
0.4
0.6
0.8 x/m
1
1.2
1.4
0.004 1.6
0 0
0.2
0.4
0.6
0.01 0.8 x/m
1
1.2
1.4
0.004 1.6
Fig. 18. Numerical Ma steady distributions at different fuel equivalent ratio in case 2
Fig. 17. Numerical normalized wall pressure steady distributions at different fuel equivalent ratio in case 2
Several key points should be identified firstly. Thermal choking is the process in which heat is added
438
to the flowfield until the flow Mach number becomes 1 no matter if initial Mach number greater or less
439
than 1.0. When thermal choking occurs along with back pressures, and the flow can only be adjusted
440
via a shock. The heat release and area change are coupled to decelerate or accelerate the flow. For
441
supersonic flow, diverging area makes pressure decline, and heat release makes pressure rise. When
442
fuel equivalent ratio is less than 0.3, pressure is in the condition of declining in the first stage heat
443
release region, so the effect of area change dominates at the moment. On the contrary the heat release
444
dominates. When fuel equivalent ratio is between 0.3 and 0.5, enormous heat release causes a pressure
445
rise and Mach number decrease. Here, Mach number has not yet met the sonic limit caused by thermal
446
choking. When fuel equivalent ratio is equal to 0.5, it is noted that the flow has choked at the second
447
stage heat addition region. Subsonic flow can be found in the rear part of the combustor, but in the
448
front part flow is supersonic, so combustion is in transition mode. As fuel equivalent ratio continues to
449
increase, pressure peak rises due to stronger thermal choking, and shock wave travels upstream to
450
decelerate the flow. Until fuel equivalent ratio reaches 1.0, the whole flowfield is subsonic, and
451
combustion is in subsonic combustion mode. As a whole, combustion realizes transition from scram
452
mode to ram mode with fuel equivalent ratio increasing. Behind the second stage heat release region,
453
heat release process is over, the flow is accelerated in the constant area and diverging area of the
454
combustor, leading to pressure decreasing and Mach number increasing. The area change shifts the
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17
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flow towards the supersonic in nozzle region. Isolator can tolerate a certain amount of backpressure, so in the flow direction the static pressure
457
decreases and Mach number increases to match combustor entrance condition. Isolator shock train
458
model using Billig’s empirical method is accounted in this paper. In case 2, in the engine isolator
459
entrance Mach number is fixed at 2.5 and it is equal with no accelerating of engine. Therefore, as more
460
heat is continuously added to a combustor, the pre-combustion shock train becomes stronger, and
461
pressure ratio can reach to 3.2.
462
4.3. Control law analysis
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For dual-mode scramjet combustor, there exist at least two kinds of boundaries for control research.
464
Unstart boundary and over-temperature boundary are important safety control boundaries of them.
465
During the ascent process of vehicle, combustor always works close to safety boundary so as to obtain
466
a high performance. The safety boundary codetermined by unstart and over-temperature will be
467
conducted in this section.
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As is known that the divergent structure is beneficial to accommodate more heat release and improve
469
the combustor performance. In the case of same total fuel equivalence ratio, the larger the first stage
470
fuel equivalence ratio is, the higher the performance of combustor is, the easier unstart phenomenon
471
happens [42]. Hence, this paper only investigates the first stage fuel maximum equivalence ratio when
472 473
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Y, is fixed at 0.5. Incoming flow conditions of combustor are from case 1, 2 and 3 listed in Table 1. Others are obtained by interpolation. In addition, accounting for thermal protection system in passive
cooling combustor, we define the maximum total temperature allowed of gas in combustor outlet as
475
2100K.
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At a fixed incoming flow Mach, with the increasing of the first fuel equivalence ratio, working state
477
of combustor gradually tends to unstart. The first stage fuel maximum equivalence ratio allowed which
478
can be found in y-axis is unstart boundary. Like this, with the increasing of the first fuel equivalence
479
ratio, the total temperature of gas in combustor outlet will gradually rise. When gas in combustor outlet
480
is 2100K, the first fuel equivalence ratio is maximum under the over-temperature restrict. It is called
481
over-temperature boundary. For a same incoming flow Mach, the less value of the first stage fuel
482
maximum equivalence ratio is chosen under the limit of unstart boundary and over-temperature
483
boundary. Using this way, the safety boundary is obtained under unstart boundary and
484
over-temperature boundary as shown in Fig. 19.
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Over-temperature boundary
Unstart boundary
φ1
0.4 0.3 0.2
2.1
2.3
Ma
2.5
2.7
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0.1
Fig. 19. Safety working region of combustor under unstart boundary and over-temperature boundary
When Mach is less than 2.3, combustor is mainly limited by unstart boundary. With the increasing of
486
Mach, the first stage fuel maximum equivalence ratio which can be injected in combustor increases
487
gradually. When Mach is between 2.3 and 2.5, the main safety risk of combustor working state transits
488
from unstart to over-temperature. When Mach is greater than 2.5, the first stage fuel maximum
489
equivalence ratio decreases gradually due to the limit of over-temperature boundary.
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490
In conclusion, different fuel equivalence ratio has effect on the distance between current working
491
state and safety boundary. The larger the fuel equivalence ratio is, the nearer the distance away from
492
safety boundary is. But safety boundary of combustor does not change. Only in this way which
493
combustor adopts variable geometry or active cooling, will safety boundary rise up, will safety working
494
region of combustor enlarge.
5. Conclusions
496
In order to develop a control-oriented model to meet the real-time requirements of control design and
497
evaluation, we have followed an approach that restricts the numbers of the physical problem at hand,
498
rather than simply compute a large table of flowfield structure data over a wide range of operating
499
conditions. This paper limits the dimension of the physical problem as much as possible, presents a
500
real-time simulation method. The model is solved at each time step. It means that upon use for control
501
design and evaluation the boundary condition is not limited by pre-specified bounds, which exist in
502
performance table. Flowfield parameter distributions can be computed at a desired operating condition
503
directly. The conclusions are summarized as follows:
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504
(1) A 1-D unsteady flow model is developed and combustion is simplified into mass and heat
505
addition process. This paper presents a heat release distribution obtaining method that can be applied in
506
scramjet combustor 1-D flowfield simulation. Using this method and utilizing several existing
507
experimental data, the heat release distribution which is fit for certain scramjet combustor
508
configuration and is acceptable over a wide range of inflow conditions can be found. This model can
509
simulate transition process between ram-mode and scram-mode operation,and numerical results can
510
agree well with experiments.
511
(2) By mixed programming of C and Matlab, the control-oriented model is built on SIMULINK 19
ACCEPTED MANUSCRIPT platform. When the model runs in a single-core 3.6GHz Intel Core i7-4790 processor, computation
513
time-consuming is found to require 5-10ms within a control period. The computing speed indicates
514
very promising, because model is compact enough to run in real time and it can be used as an
515
embedded model in control system research. Utilizing this model, unsteady and steady flowfield
516
characteristic can be analyzed in the scramjet combustor. The safety boundary codetermined by unstart
517
and over-temperature is conducted in the end of this paper.
Acknowledgments
518
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This research work is supported by National Natural Science Foundation of China (Grants No.
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Highlights 1.
Control-oriented 1-D unsteady model was presented for dual-mode scramjet combustor.
2.
By mixed programming, real-time model was built on SIMULINK platform.
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3. The heat release distribution obtaining method was discussed and explained. 4. The unsteady, steady flowfield process and safety boundary were analyzed.