Multi-Feature Fusion Based Adaptive Surge Detection Method for Aero-Engine Compressors

Compressor surge poses a critical safety risk for aero-engines. However, conventional physics-driven detection methods—relying on single-domain features and fixed empirical thresholds—struggle to adapt across varying compressor configurations, wide operating ranges, and complex interference environments. This paper proposes a multi-feature fusion adaptive surge detection method that integrates time-domain amplitude, frequency-weighted power and slope features within a joint threshold criteria, enabling reliable and adaptive surge detection according to the statistical characteristics of the signal itself. A wavelet-based preprocessing strategy is established with the db4 wavelet and four-level decomposition identified as the optimal setting through systematic evaluation. A novel feature FWP is introduced herein, which applies frequency-dependent weighting to the power spectral density to suppress noise components while amplifying energy changes within surge-relevant bands, achieving 1.7 to 6.1 times greater magnitude variation near the surge point compared with total spectral power. The slope feature is further discovered to distinguish surge from transient interferences such as rapid valve throttling, fuel stepping and rapid acceleration. Among 100 samples, the three-feature joint detection strategy integrated with adaptive threshold criteria improves accuracy from 61% to 98%. A Bayesian optimization framework using Gaussian process surrogate models is developed for efficient cross-engine hyperparameter tuning, converging to optimal solutions within merely 11 to 13 iterations across two distinct compressors. Lastly, the method is implemented on an NI cRIO-based real-time platform and validated on two distinct ten-stage high-pressure compressors, covering surge tests across a wide speed range of 45% to 98%. Comparative tests against an industry-standard reference device demonstrate earlier warning lead times of 41 to 99 ms. The results confirm that the proposed method herein achieves high accuracy, strong robustness against operational interferences, and good cross-platform adaptability for practical application.