In 2022, APEX responded to a Request for Quotation (RFQ) from Safran Test Cells for their project to design and build the new BeCOVER test facility. BeCOVER, located near Liège in Belgium, is an independent compressor test centre designed to test both civil and military applications. The specifications met by the test bench have been defined for both current and future engine architectures. The test centre has state-of-the-art technology and aims to support engine development for the next 40 years. Its configuration, performance, and infrastructure are designed to keep pace with future developments in the aeronautical industry. The wide range of performances (power, pressure, temperatures, etc.), coupled with the test bed’s ability to carry out altitude tests for all engine operating conditions, makes BeCOVER a unique centre in Europe, if not the world. From a technical point of view, the mechanical shaft power available at BeCOVER (up to 30MW) means that the tests can be carried out at scale 1 and under representative pressure and temperature. This capacity means that the compressor can be tested under optimum conditions from an aerodynamic point of view, enabling aeromechanical characterisation to be carried out at a very early stage in the development process. The facility is equipped with state-of-the-art instrumentation, measurement, and data acquisition resources that combine precision, reliability, and representativeness of the physical phenomena observed.
The BeCOVER project required a Dynamic Data Acquisition System (DDAS) to support high-speed, high-resolution measurement and monitoring within a compressor test facility. The DDAS was expected to handle multiple sensor types and meet stringent environmental and performance specifications. Key requirements included:
- Capability to measure 142 channels simultaneously, with a modular solution allowing for future expansion.
- Support for multiple sensor types, including voltage, strain gauge, vibration, unsteady pressure, and rotational speed measurements.
- High sampling rates of up to 204.8 kSamples per second per channel, with configurable frequency options.
- Built-in signal conditioning, anti-aliasing filters, and precise synchronization.
- Hardware designed to operate in a wide range of temperatures and humidity levels.
- Software integration for real-time monitoring, data visualization, and post-analysis using standard plots like FFT, Campbell, and Waterfall diagrams.
- Data archival solutions with RAID storage configurations capable of retaining many hours of high-speed test data.
- Compliance with European CE standards and Safran-specific test cell operational protocols.
APEX provided a modular and synchronized data acquisition system that met all specified requirements. The solution included three MeCalc Chassis, each connected to an APEX host controller.
APEX’s software fulfilled the initial portion of BeCOVER’s requirements. The provided solution included:
APEX DS (Data System)
A fully scalable, feature-rich data acquisition software that facilitates setup, synchronization, and monitoring of high-speed data from multiple channels. DS supports real-time frequency-domain processing, integrates seamlessly with hardware from leading manufacturers, and offers an open architecture API for custom plugin development.
APEX DR (Dynamic Real-Time Monitoring)
Provides real-time monitoring and visualization with customizable dashboards. DR enables engineers to analyze and track live data using FFT processing, spectral window functions, and multi-page displays with synchronized data streams. DR ensures signal health monitoring with real-time alerts for over-range signals.
APEX DX (Data Analysis & Reporting)
A powerful post-processing software with an intuitive drag-and-drop interface. DX facilitates data analysis in the time, frequency, and order domains. It includes advanced digital filtering, order tracking, and ensures consistent and repeatable results with its graphical setup. DX also provides robust reporting tools for summarizing results.
MeCalc’s hardware addressed the remaining requirements for the BeCOVER project. APEX software seamlessly connects to MeCalc hardware, ensuring a complete, turnkey solution. The MeCalc system’s modularity provided unparalleled customization and scalability, allowing components to be upgraded independently as testing requirements evolved.
Key features of the MeCalc system:
- Support for a wide range of sensors, including ICP, voltage, tachometer, and strain gauges.
- Built-in signal conditioning.
- Synchronization over multiple chassis.
- Ruggedized design enabling operation in a wide range of testing environments.
- Built-in batteries for uninterrupted power supply.
APEX provided a 144-channel Dynamic Data Acquisition System distributed over three MeCalc hardware chassis with included software for data acquisition, processing, visualization, and reporting:
DecaQ System 1
- 46 Channels ICP®/Voltage
- 2 Channels Tachometer
DecaQ System 2
- 48 Channels ICP®/Voltage
DecaQ System 3
- 48 Channels Bridge/ICP®/Voltage
Each MeCalc chassis is controlled by an APEX host controller, a DELL Precision 7920 Rack Workstation server, featuring:
- Dual Intel Xeon Gold 6230 CPU
- 64GB 8x8GB DDR4 2933MHz memory
- Approximately 80TB of storage
- Windows 10 operating system
APEX was chosen for the BeCOVER project because its solution not only met the demanding technical requirements but also delivered exceptional value through competitive pricing and a proven history of high-performance data acquisition solutions. The integration of APEX’s software with MeCalc hardware provided a seamless and efficient testing experience, giving Safran Aero Boosters a powerful edge in their data acquisition and analysis processes.
By selecting APEX, Safran Aero Boosters equipped the BeCOVER facility with a future-ready solution that enhances accuracy, reliability, and operational efficiency. As BeCOVER’s testing needs evolve, they continue to rely on and expand their use of APEX products, acquiring additional software licenses and integrating APEX solutions with other systems to maximize performance and streamline their testing capabilities.
