12 reviews

Jet Engine TestingInstrumentation for complete testing of jet engines

Advanced data acquisition solutions for comprehensive jet engine testing. From performance and environmental testing to durability, acoustic, and vibration analysis, our systems ensure precise measurements under extreme conditions. Designed for certification compliance, including regulatory tests like bird strikes and blade containment, we provide reliable tools for optimizing engine performance, safety, and durability.

15 MS/s/ch

5 MHz bandwidth

-40°C to +85°C

Acceleration

Voltage

High Voltage

Current

AC current

DC current

IEPE

Charge

Differential

Full Bridge

Half Bridge

Quarter Bridge

Pressure

Force

Temperature

RTD

Thermocouple

Thermal video

Digital IO

Counter and Encoder

Analog out

ARINC 492

CAN bus

CAN FD

Dynamic signal analysis

FFT analyser

Balancing

CAN out

EtherCAT

Data logger

Displacement

Distance

DSI compatible

Ethernet

Fanless

Frequency

Full HD

Galvanic isolation ±1000 V

GPS and GLONASS

Gyroscope

HDMI

High-speed video

Inertial platforms

iNET

IP67

IRIG and GPS timecode

IRIG Chapter 10

IRIG Chapter 7

Isolation CAT II 1000 V

Isolation CAT III 600 V

LAN

MIL-STD-1553

openDAQ compliant

Order tracking

PoE (Power Over Ethernet)

PTP synchronization

PWM

Resistance

RPM

Sequencer

Shock rating 100g

Serial

Sound

Sound pressure

Stress and Strain analysis

Strain and Stress

TEDS compatible

Torque

USB 3.0

Velocity

Vibrations

Video

Jet Engine Testing highlights

High-Resolution Data Acquisition

High-speed jet engines generate fast and complex signals. To capture every detail, DAQ systems require high-resolution performance. Our solutions provide sampling rates in the MHz range with 24-bit resolution, which is ideal for vibration and acoustic measurements.

High Sampling Rate and Large Data Handling

Jet engines generate extremely high-frequency signals, particularly in vibration and acoustic domains. To manage this, the software must support high sampling rates (up to the MHz range) and handle large datasets efficiently. Dewesoft’s real-time data compression and scalable storage solutions provide an ideal solution.

Scalability and Modularity

Jet engine tests often involve hundreds of sensors across various domains, such as thermal, mechanical, and acoustic. A modular system ensures easy scaling and customization. With Dewesoft’s flexible architecture, you can configure channels effortlessly at any time.

Remote Monitoring and Control

Modern test facilities cover large areas, making remote monitoring and control essential. Engineers need real-time access to data and system controls from anywhere. Dewesoft provides multiple solutions for seamless remote integration with our measurement systems.

Data Security and Integrity

Jet engine testing generates sensitive data that must be protected from unauthorized access or loss. Dewesoft ensures security with encrypted data storage and secure communication protocols, making it a trusted choice for jet engine manufacturers.

Multi-Physics Integration

Jet engine testing involves measuring various physical phenomena simultaneously, including vibrations, acoustics, temperature, pressure, and emissions. Dewesoft DAQ hardware and software seamlessly integrate these data types, supporting multi-domain data collection and analysis, such as time-domain and frequency-domain.

Multi-Protocol Support

Jet engines rely on systems that communicate using various protocols, such as CAN FD, ARINC 429, and Ethernet/IP. Dewesoft’s advanced communication capabilities enable seamless integration of our DAQ systems with these protocols.

Environmental Durability

Jet engine tests often take place in extreme environments, involving intense heat, cold, and vibration. DAQ hardware must be built to endure these challenges. Dewesoft’s rugged, weatherproof, and shock-resistant design ensures reliable operation across a wide temperature range.

Data Compression and Storage

Continuous testing produces massive datasets, demanding efficient storage and retrieval. Dewesoft offers real-time data compression, ample local storage, and seamless cloud integration, making it an excellent solution for data recording.

Automated Test Sequencing

Dewesoft’s user-programmable test sequences and trigger-based automation are perfect for repetitive and standardized testing. Automation saves time and minimizes human error.

Comprehensive Health Monitoring

Continuous health monitoring of the DAQ system is essential for reliability during critical tests. Dewesoft provides built-in diagnostics and alert systems to detect hardware and software anomalies.

Real-Time Data Fusion

Jet engine tests involve data from multiple sources, such as thermal, mechanical, and electrical systems. Dewesoft hardware enables real-time fusion of multi-physics data for comprehensive analysis.

Easy Integration with Legacy Systems

Many facilities operate older systems alongside new ones. Compatibility ensures smooth upgrades without replacing existing infrastructure. Backward compatibility with legacy hardware and software.

Synchronous Data Acquisition (PTP v2)

High-precision synchronization ensures that data from multiple sensors (e.g., pressure, temperature, vibration) aligns perfectly in time. Jet engine testing often involves hundreds of sensors, and any time skew can lead to inaccurate results. Dewesoft’s perfect time-stamped data uses GPS or IEEE 1588 Precision Time Protocol (PTP).

Order Tracking Analysis

Dewesoft enables real-time tracking of harmonics (orders) as rotational speed changes. Jet engines feature rotating components like fans, compressors, and turbines, where order tracking analyzes vibrations and rotational dynamics relative to engine speed. This is vital for detecting issues such as unbalanced rotors or blade vibrations.

Real-Time Data Visualization and Analysis

Dewesoft offers real-time tools like FFT displays, spectrograms, and order plots, providing engineers with instant feedback during tests. This allows for real-time monitoring of parameters such as thrust, fuel flow, and vibration levels. Immediate analysis helps identify issues without waiting for post-test processing.

Advanced Post-Processing and Reporting Tools

Complex testing produces large volumes of data that must be analyzed and presented clearly. Dewesoft’s post-processing tools streamline this process with automated analyses and easy report generation. Features like signal filtering, statistical tools, and automated reporting are just a click away.

User-Friendly Interface and Customization

Dewesoft’s drag-and-drop display configuration and modular analysis options provide exceptional flexibility for daily testing operations. Complex tests often involve engineers and technicians with diverse needs. A user-friendly interface and customizable workflows enhance efficiency and minimize errors.

Dewesoft quality and 7-year warranty

Enjoy our industry-leading 7-year warranty. Our data acquisition systems are made in Europe, utilizing only the highest build quality standards. We offer free and customer-focused technical support. Your investment into the Dewesoft solutions is protected for years ahead.

Software included

Every Dewesoft data acquisition system is bundled with award-winning DewesoftX data acquisition software. The software is easy to use but very rich and deep in functionality. All software updates are free forever with no hidden licensing or yearly maintenance fees.

Jet Engine Testing Solution Overview

Jet engine testing is a critical process in the aerospace industry, ensuring the safety, efficiency, and reliability of one of the most vital components in aviation. Tests involve evaluating various parameters such as vibrations, acoustics, temperature, pressure, emissions, and thrust under different operating conditions. By replicating real-world scenarios, engineers can identify potential issues, improve performance, and comply with stringent regulatory standards.

Testing is essential because jet engines operate in extreme environments, enduring high temperatures, pressures, and rotational speeds. The data collected during testing provides valuable insights into engine durability, fuel efficiency, and noise reduction, which are crucial for meeting environmental and safety requirements. Without rigorous testing, even minor flaws could lead to costly failures or compromise passenger safety.

Dewesoft’s Jet Engine Testing Solutions are designed to meet these challenges with cutting-edge hardware and software. Our systems enable seamless multi-domain data acquisition, real-time analysis, and powerful post-processing tools. With flexible, modular designs and user-friendly interfaces, Dewesoft ensures precision, efficiency, and reliability in every phase of jet engine testing.

Delta Jet Engine Test Cell Facility, Delta News Hub, CC BY 2.0 via Wikimedia Commons

The critical requirements for jet engine testing

While many features are critical in specific contexts, order tracking analysis, synchronous data acquisition, and real-time visualization are often the most essential for dynamic testing of jet engines. Together, they provide the tools needed to analyze high-speed rotational dynamics, detect faults, and validate performance under extreme conditions.

Electrical power measurements are critical for assessing the performance and efficiency of new-generation jet engines, especially as the industry explores hybrid-electric, all-electric, and next-generation fuel systems. These measurements evaluate how effectively engines convert energy into usable power, ensuring reliability, safety, and sustainability.

Example of an order analysis measurement display

Facilities for Jet Engine Testing

Ground Test Cells: Enclosed, stationary facilities where engines are securely mounted for testing. Examples include GE’s renowned Peebles and Evendale facilities.
Altitude Test Chambers: Specialized chambers replicating high-altitude conditions, including low pressure and temperatures, to assess engine performance at cruising altitudes.
Open-Air Test Sites: These are outdoor testing locations designed to measure noise, emissions, and environmental impacts in real-world conditions.

Dewesoft provides flexible and powerful data acquisition systems tailored for every type of jet engine testing facility and scenario. Whether it’s ground test cells, altitude chambers, or open-air test sites, our modular hardware and advanced software ensure precise and reliable multi-domain data acquisition. From performance analysis to environmental impact assessment, Dewesoft solutions adapt seamlessly to meet the demands of each testing environment.

Jet engine testing facility with jet engine mounted and prepared for test

Types of Jet Engine Testing

There are many different tests being performed during the development, production, and qualifications of gines and Dewesoft's extensive and flexible DAQ devices can be used in any of these tests:

Performance Testing: Measures thrust, fuel efficiency, and overall engine performance under controlled conditions. These tests evaluate key metrics like maximum thrust, specific fuel consumption, and power output.
Environmental Testing: Simulates extreme conditions, including temperature changes, high-altitude environments, and saltwater exposure, to ensure engines can perform reliably in diverse operating environments.
Durability and Reliability Testing: Engines are subject to prolonged operations and stress conditions to identify wear and fatigue points. This includes cyclic testing to replicate repeated take-offs and landings.
Acoustic Testing: Assesses noise levels produced by engines to comply with environmental regulations, focusing on reducing sound pollution and minimizing environmental impact.
Vibration and Structural Testing: Analyzes how engines respond to mechanical vibrations during operation to ensure the structural integrity and durability of engine components.
Certification Testing: Comprehensive testing is required to meet regulatory standards (e.g., FAA, EASA). This includes failure tests like bird strike simulations and blade containment tests to validate safety and performance.

Environmental Measurements

Environmental testing is crucial for understanding how jet engines perform under various real-world conditions:

Altitude simulation evaluates engine performance in low-pressure, high-altitude environments using instruments like pressure transducers and barometers.
Temperature extremes testing examines how engines operate in both hot and cold climates, relying on tools such as thermocouples and infrared sensors.
Icing conditions tests simulate environments with ice buildup to ensure reliable performance.

These tests use water injection systems and temperature sensors to replicate and monitor the effects of icing on engine components.

Jet engine testing with ice formed on nose cone

Structural and Vibration Measurements

Structural and vibration testing is essential to ensure the durability and reliability of jet engines.

Vibration levels are monitored to detect vibrations caused by engine operation, safeguarding the structural integrity of components. This is achieved using instruments such as accelerometers and strain gauges.
Stress and strain testing evaluates the stress on engine components during operation, using advanced strain gauges and stress analysis systems to identify potential weaknesses.
Blade dynamics testing focuses on the movement and vibrations of fan and turbine blades, employing non-contact displacement sensors and laser Doppler vibrometers for precise measurement and analysis.

Acoustics and Noise Measurements

Acoustics and noise testing are crucial to ensure jet engines meet environmental noise regulations.

Noise levels are evaluated using microphone arrays and sound level meters to measure sound emissions and verify compliance.
Frequency analysis helps identify the sources and specific frequencies of noise, using advanced spectrum analyzers to provide detailed insights for noise reduction and optimization.

Durability and Lifecycle Testing

Durability and lifecycle testing ensure jet engines can withstand the demands of long-term operation.

Cyclic fatigue tests replicate repeated take-offs and landings to evaluate the engine’s resilience over time, using strain gauges and thermal cycling systems.
High-stress conditions testing examines engine performance during maximum power operation, employing accelerometers and stress analyzers to identify potential weaknesses and ensure reliability under extreme conditions.

Thermal Measurements

Thermal measurements play a vital role in monitoring jet engine performance and ensuring safety.

Exhaust Gas Temperature (EGT) is a key parameter for detecting abnormalities and optimizing engine efficiency, measured using thermocouples and pyrometers.
Component temperatures of critical parts such as turbines, compressors, and bearings are monitored with thermistors and temperature sensors to ensure reliable operation under demanding conditions.

Fluid Dynamics

Fluid dynamics testing is essential for understanding and optimizing jet engine performance.

Airflow rates are measured to determine the amount of air entering and exiting the engine using instruments like Pitot tubes and flow meters.
Pressure ratios are analyzed to evaluate the efficiencies of compressors and turbines, relying on precise pressure transducers.
Fuel flow is monitored to measure the rate of fuel delivery, with flow meters providing accurate data for performance and efficiency analysis.

Operational Safety Testing

Operational safety testing is critical to ensure jet engine reliability under all conditions.

Surge and stall detection focuses on identifying unstable airflow through the engine, using pressure transducers and airflow sensors to monitor these events.
Blade containment testing evaluates the engine’s ability to contain fragments during a blade failure, relying on high-speed cameras and pressure sensors to capture and analyze these critical safety scenarios.

Data Acquisition Hardware for Jet Engine Testing

Jet engine testing often requires conducting multiple measurements simultaneously, involving thousands or more input channels. Dewesoft’s flexible and modular architecture is specifically designed to meet these demands.

Multi-physics inputs

Dewesoft is the perfect choice for today’s precise and fast testing needs. It supports multi-physics inputs, including vibrations, acoustics, temperature, pressure, and emissions. With multi-domain capabilities, it enables both time-domain and frequency-domain analysis, ensuring comprehensive and accurate results.

Scalability and modularity

Scalability and modularity are essential for jet engine tests, which often involve hundreds of sensors across various domains, including thermal, mechanical, and acoustic. Dewesoft’s modular systems ensure easy scaling and customization. With our flexible architecture, channels can be configured effortlessly at any time, saving both time and resources.

High-resolution data acquisition

High-speed jet engines produce fast and complex signals that require high-resolution data acquisition. Dewesoft’s hardware deliver astonishing dynamig range with 24-bit resolution, making them ideal for capturing every detail in vibration and acoustic measurements. This ensures that no critical data is missed during testing.

High sampling rate

Jet engines generate extremely high-frequency signals, especially in the vibration and acoustic domains. Dewesoft’s systems are built to handle these challenges with high sampling rates (up to the MHz range) and the ability to manage large datasets efficiently. Real-time data compression and scalable storage solutions make Dewesoft an excellent choice for demanding data acquisition tasks.

Open by default! Fully openDAQ compliant hardware.

You’ve probably heard of openDAQ™—an open standard for measurement devices. It’s a collaborative venture between Dewesoft and HBK, two leading DAQ system manufacturers.

With its powerful open-source toolbox, openDAQ™ makes it easy to discover, stream, and configure data, giving engineers worldwide unmatched compatibility, flexibility, and efficiency.

Dewesoft DAQ hardware is fully openDAQ-compliant and open by default (*), allowing seamless integration into your existing workflows. The openDAQ SDK simplifies device discovery, setup, and data streaming like never before.

To help you get started, openDAQ provides examples on integrating the SDK. With AI-powered tools, you can integrate and access data from Dewesoft hardware in seconds.

* Currently only SIRIUS® XHS, SIRIUS® X, IOLITE® X, and OBSIDIAN® familly of products are openDAQ-compliant.

Data Acquisition Software for Jet Engine Testing

Dewesoft’s easy-to-use software helps set up DAQ hardware and process data quickly. This saves time and money for engineers. With its easy-to-use interface, engineers can improve their workflows. They can reduce errors and focus more on analysis and results instead of system setup.

After 25 years of software development and many hours of improvements, we have made award-winning data acquisition software. We have earned the trust of thousands of engineers around the world.

Real-time data visualization and analysis

Dewesoft delivers real-time visualization tools like FFT displays, spectrograms, and order plots, giving engineers immediate feedback during tests. This enables real-time monitoring of critical parameters, such as thrust, fuel flow, and vibration levels. Identifying issues instantly reduces downtime and eliminates the need to wait for post-test analysis.

Advanced Post-Processing and Reporting Tools

Dewesoft’s post-processing capabilities simplify the analysis of complex datasets and the creation of clear, actionable reports. Automated tools for signal filtering, statistical analysis, and report generation streamline workflows, saving time and effort. These features ensure that even the most intricate testing data can be interpreted and shared efficiently.

User-Friendly Interface and Customization

Dewesoft’s intuitive drag-and-drop interface and customizable analysis options make configuring data acquisition hardware and workflows simple. This flexibility is especially valuable in complex testing environments, where diverse teams of engineers and technicians may have unique requirements. By enhancing usability and minimizing errors, our software saves valuable engineering time and reduces costs.

Electrical Power Measurements for New-Generation Jet Engines

Modern jet engines increasingly rely on advanced electrical systems for improved efficiency, performance, and environmental compliance. These systems power critical components such as electric starters, hybrid propulsion systems, and onboard generators. Testing and analyzing the electrical power performance of these components is vital to ensure their reliability and efficiency in demanding aviation environments.

Dewesoft provides state-of-the-art solutions for electrical power measurement tailored to the needs of new-generation jet engines.

With our high-precision power analyzers, you can measure parameters such as voltage, current, power, and efficiency across multiple channels. Our systems are designed to handle both AC and DC signals, enabling detailed analysis of electrical components under real-world operating conditions.

Key features include real-time power calculations, harmonic analysis, and efficiency mapping, giving engineers a comprehensive understanding of power performance. Combined with our modular architecture and synchronization capabilities, Dewesoft ensures seamless integration of electrical measurements with other critical test domains like thermal and mechanical systems. This holistic approach delivers actionable insights for optimizing next-generation jet engines.

Electrical power and efficiency testing of electrical aicraft engines