Virtual Testing Method for Multi-channel Coordinated Loading System

This paper investigates a virtual testing methodology for full-scale structural test setups of aircraft, to simulate its static and dynamic behavior and reduce the cost and risk of actual system construction. Due to the flexibility of the aircraft itself, the loading channel connection structures interact with each other, resulting in the complex coupling problem of force and position. In addition, the explicit dynamics calculation using finite element method to simulate the loading system deformation cannot meet the calculation speed requirements for controller parameter tuning. To address these issues, a virtual prototype of the aircraft structural test equipment, including the mechanical system, hydraulic system and control system, was built in this paper. The component mode synthesis method was used to simulate the flexibility of aircraft structures and loading lever system. The valve-controlled single-outlet rod hydraulic model was adopted to simulate the loading hydraulic system of each channel. The capability of the virtual testing before constructing the actual loading system was verified through static and fatigue loading simulations on 16 hydraulic loading channels. During the virtual loading process, the tested aircraft undergoes dynamic deformation at each loading point that follows the same pattern as the load spectrum under the influence of various channel loads.