Zhu, Jianfeng, Huang, Guochen, Diao, Bo, Xu, Maoguang, Wang, Jun, and Li, Po
• Object: This paper further studied the unique characteristics of turbo-generator system, which is an important development direction of future aviation power. Aiming at the real runaway failure in the ground test, this paper expounded the root cause and direct cause of runaway failure, put forward the protection method of runaway failure and carried out the experimental verification, which provided the useful references for the configuration design and ground test of series hybrid aero propulsion system. • Method: As a whole, the paper adopted the iterative research method of "test-simulation-test". Firstly, it analyzed the real phenomenon of overspeed runaway failure in the engineering system, then established a simulation model to deeply study the causes of the failure, and finally carried out the feasibility analysis of the protective actions by combining simulation with test. The special highlight is that not only the corresponding solutions to the cause of failure were put forward in this paper,but also the experimental verification was included. • Conclusion: In this paper, the main conclusions of the research on runaway failure include:1) The fundamental cause of runaway failure lies in the small rotational inertia of high-speed turbo-generator set, and the direct cause is the unbalanced relationship between power supply and demand of the microgrid; 2) If the maximum power of battery meets the requirements, the failure risk can be eliminated by control methods; 3) Once the failure inevitably occurs, the resistors can be used to consume power to prevent the situation from getting worse. • Novelty: In this paper, the failure risk of turbine disk burst in a special application scenario was discovered through ground tests. Different from the traditional aviation power plant, the root cause and direct cause of the failure in the turbo-generator set were analyzed in detail, and a simulation model was established to support the viewpoint. Secondly, compared to the traditional mechanical designs, this paper skillfully solved mechanical problems by using control methods and electric methods. Finally, the test showed that the two protective actions can effectively avoid the overspeed runaway failure. • Significance: In order to meet the development goal of higher power density of turbo-generator system, in addition to the application of special motors, Permanent Magnet Synchronous Motors show a development trend of higher speed. The failure protective actions proposed in this paper can effectively avoid or delay the occurrence of runaway failure, improve the safety performance of the high-speed turbo-generator system, and lay the foundation for the development of series hybrid aero propulsion system with higher power and speed. Based on a series hybrid aero propulsion system with power class of 200 kW, voltage of 540 V and speed of 21000r/min, proceeding from the occurrence of the runaway failure during experiment, this study reveals the characteristics and causes of a traditional turbine engine failure in a new application context, focuses on optimizing mechanical issues from the perspective of control strategies and electrical equipment, combined with mechanism analysis and experimental validation. The main conclusions are as follows: the fundamental reason for the high-speed turbo-generator set facing the risk of overspeed runaway is the small rotational inertia of the rotor system, with the direct cause being the power imbalance between the supply side and the demand side of the propulsion system. Experimental verification demonstrated that the active protection scheme based on voltage regulation by battery can keep the speed and voltage of turbine-generator set fluctuations below 0.3 % and adjustment time within 0.5 s for load changes within the battery power range, effectively preventing runaway failures caused by minor power fluctuations. Additionally, the passive protection scheme based on power dissipation through resistors reduced the speed of the power turbine from 7000r/min to 2000r/min no more than 2 s, indicating the effectiveness of this measure in restricting the speed within a safe range. [ABSTRACT FROM AUTHOR]