Engine effector position measurement

Abstract

A system for engine effector position measurement includes an effector actuator of an engine, the effector actuator including a housing and one or more movable elements for changing an effector position of an effector coupled to the effector actuator, and a time of flight (TOF) sensor configured to detect a time of flight (TOF) of the engine. The time of flight (TOF) sensor is within a housing of the effector actuator and is positioned to measure a distance between the TOF sensor and a reflective surface within the housing to determine an effector position of the effector.

Description

Technical Field

[0001] The present subject matter relates generally to engines, and particularly to engine effector position measurement. Background Art

[0002] Turbine engines may include variable geometry effectors, such as variable pitch blades, which can be actuated to affect engine output and fuel consumption. Precise control of these effectors is important for optimizing engine performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] A full and enabling description of the disclosure, including the best mode thereof, for those skilled in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0004] Figure 1 is a cross-sectional side view of an embodiment of a propulsion system according to some embodiments;

[0005] Figure 2 is a simplified block diagram of an engine control system according to some embodiments;

[0006] Figure 3 is a flow chart of a method for effector position measurement and control according to some embodiments;

[0007] Figure 4A and Figure 4B is a diagram of an engine effector according to some embodiments; and

[0008] Figure 5A and Figure 5B is an illustration of a sensor system with calibration according to some embodiments. DETAILED DESCRIPTION

[0009] Reference will now be made in detail to the embodiments of the present disclosure, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the present disclosure and is not intended to limit the present disclosure. Indeed, it will be apparent to those skilled in the art that various modifications and variations may be made to the present disclosure without departing from the scope or spirit of the present disclosure. For example, features shown or described as part of one embodiment may be used together with another embodiment to produce yet another embodiment. Therefore, the present disclosure is intended to encompass such modifications and variations as fall within the scope of the appended claims and their equivalents.

[0010] As used herein, the terms "first," "second," "third," etc. may be used interchangeably to distinguish one component from another and are not intended to indicate the position or importance of each component.

[0011] Unless otherwise specified herein, the terms "coupled," "fixed," "attached," and the like refer to both direct coupling, fixing, or attachment as well as indirect coupling, fixing, or attachment through one or more intermediate components or features.

[0012] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0013] As used herein throughout the specification and claims, approximate language can be used to modify any quantitative representation that can allow variation without causing the basic function associated therewith to change. Therefore, the value modified by one or more terms (such as "about", "approximately", "almost" and "substantially") is not limited to the exact value specified. In some cases, approximate language may correspond to the precision of the instrument used to measure the value. For example, approximate language may refer to within a margin of 1%, 2%, 4%, 10%, 15% or 20%. These approximate margins can be applied to a single value, to define any one or two endpoints of a numerical range and / or the margin of the range between the endpoints. Here and throughout the specification and claims, range limitations are combined and interchanged. Unless otherwise indicated by context or language, such ranges are identified and include all subranges contained therein. For example, all ranges disclosed herein include endpoints, and endpoints can be independently combined with each other.

[0014] For variable geometry engines, variable geometry effectors, such as variable pitch blades and vanes, can be controlled based on a feedback loop that includes effector position sensors (e.g., pitch measurement sensors). In such engines, the accuracy of the sensors affects the precision of the engine's variable geometry control. Sensor design also impacts the overall form, reliability, and durability of the engine.

[0015] Effector position measurement can be performed via mechanical linkages, optical sensors, or magnetic sensors. However, existing methods often face challenges such as mechanical wear, susceptibility to environmental conditions, and interference from other engine components.

[0016] In some aspects, an effector position measurement system is provided for variable geometry propulsion applications. The system may include associated hardware, one or more sensing elements, associated signal processing software or hardware modules, and a computational device for obtaining effector position, such as the pitch angle (also referred to as β). In some embodiments, the position measurement system determines actuator position by measuring axial displacement of the actuation system.

[0017] In some embodiments, the system measures pitch angle by using one or more ultrasonic sensors located within the actuator cylinder to measure the distance to a relevant surface from which mechanical waves within the actuator are reflected. The actuator cylinder can be filled with pressurized oil or other working fluid. By measuring the "time of flight" for the mechanical wave to travel from the sensor to the reflecting surface and back, the axial displacement (and thus the effector position) can be obtained.

[0018] In some embodiments, the sensing system is configured for self-calibration to be more robust and accurate in different media with varying properties. In some embodiments, the sensor includes a reflective surface at a known distance from the sensor for calibration. In some embodiments, the sensor system includes an additional layer of known medium adjacent to the reflective surface, where the total energy is distributed such that some energy is reflected and a portion of the energy passes through the additional medium toward the reflective surface. The delta time between the time of flight of the reflected signal on the reference medium and the reflective surface can be used to calibrate the time-of-flight variation used for distance measurements.

[0019] Now refer to Figure 1 , a schematic cross-sectional view of a gas turbine engine 100 is provided, according to an exemplary embodiment of the present disclosure. The effector position measurement methods and systems described herein may be implemented within one or more actuators of the engine 100.

[0020] However, it should be understood that Figure 1 The exemplary single-spool, non-ducted engine 100 shown in FIG is provided as an example only, and in other exemplary embodiments, the engine 100 may have any other suitable configuration, including, for example, any other suitable number of shafts or spools, turbines, compressors, etc.; fixed-pitch blades, a direct drive configuration (i.e., the gearbox 155 may not be included); and the like. For example, in other exemplary embodiments, the engine 100 may be a three-spool engine with a medium-speed compressor and / or turbine. In such a configuration, it should be understood that the terms "high" and "low," as used herein with respect to turbine, compressor, or spool speeds and / or pressures, are used for convenience in distinguishing between components, but do not require any particular relative speeds and / or pressures and do not preclude additional compressors, turbines, and / or spools or shafts.

[0021] Additionally or alternatively, in other exemplary embodiments, any other suitable gas turbine engine may be provided. For example, in other exemplary embodiments, the gas turbine engine may be a turboshaft engine, a turboprop engine, a turbojet engine, a rotorcraft engine, a ducted engine with variable-pitch blades, or the like. Furthermore, for example, while the engine is depicted as a single, unducted rotor engine, in other embodiments, the engine may include a multi-stage open rotor configuration or a ducted engine, and the disclosed aspects described herein below may be incorporated therein.

[0022] Figure 1 An engine 100 is provided having a rotor assembly with a single stage of unducted rotor blades. In this manner, the rotor assembly may be referred to herein as a "unducted fan," or the entire gas turbine engine 100 may be referred to as a "unducted engine," or an engine having an open rotor propulsion system 102. In addition, Figure 1 The engine includes a mid-fan flow path extending from the compressor section to the rotor assembly above the turbine, as explained in greater detail below. It is also contemplated that, in other exemplary embodiments, the present disclosure is compatible with engines having a duct surrounding an unducted fan. It is also contemplated that, in other exemplary embodiments, the present disclosure is compatible with turbofan engines having a third flow path as described herein.

[0023] For reference, the gas turbine engine 100 defines an axial direction A, a radial direction R, and a circumferential direction C. Furthermore, the gas turbine engine 100 defines an axial centerline or longitudinal axis 112 extending along the axial direction A. Generally, the axial direction A extends parallel to the longitudinal axis 112, the radial direction R extends outwardly from and inwardly to the longitudinal axis 112 in a direction orthogonal to the axial direction A, and the circumferential direction extends three hundred and sixty degrees (360°) about the longitudinal axis 112. The gas turbine engine 100 extends between a forward end 114 and an aft end 116, e.g., along the axial direction A.

[0024] The gas turbine engine 100 includes a turbine 120 (also referred to as the core of the gas turbine engine 100), and a rotor assembly (also referred to as a fan section 150) positioned upstream thereof. Generally, the turbine 120 includes a compressor section, a combustion section, a turbine section, and an exhaust section in a series flow order. Specifically, as shown in FIG. Figure 1 As shown, the turbine 120 includes a core shroud 122 that defines an annular core inlet 124. The core shroud 122 also at least partially surrounds a low-pressure system and a high-pressure system. For example, the core shroud 122 shown at least partially surrounds and supports a supercharger or low-pressure ("LP") compressor 126 for pressurizing air entering the turbine 120 through the core inlet 124. A high-pressure ("HP"), multi-stage, axial-flow compressor 128 receives the pressurized air from the LP compressor 126 and further increases the pressure of the air. The pressurized air flows downstream to the combustor 130 of the combustion section, in which fuel is injected into the pressurized air flow and ignited to increase the temperature and energy level of the pressurized air and produce high-energy combustion products.

[0025] It should be understood that, as used herein, the terms "high / low speed" and "high / low pressure" are interchangeable for high-pressure / high-speed systems and low-pressure / low-speed systems. Furthermore, it should be understood that the terms "high" and "low" are used in the same context to distinguish between the two systems and are not meant to imply any absolute speed and / or pressure values.

[0026] The high-energy combustion products flow downstream from the combustor 130 to a high-pressure turbine 132. The high-pressure turbine 132 drives the high-pressure compressor 128 via a high-pressure shaft 136. In this regard, the high-pressure turbine 132 is drivingly coupled to the high-pressure compressor 128. The high-energy combustion products then flow to a low-pressure turbine 134. The low-pressure turbine 134 drives the low-pressure compressor 126 and components of the fan section 150 via a low-pressure shaft 138. In this regard, the low-pressure turbine 134 is drivingly coupled to components of the low-pressure compressor 126 and the fan section 150. In this example embodiment, the low-pressure shaft 138 is coaxial with the high-pressure shaft 136. After driving each of the turbines 132, 134, the combustion products exit the turbine 120 through a core or turbine exhaust nozzle 140.

[0027] Thus, the turbine 120 defines a working gas flow path or core duct 142 that extends between the core inlet 124 and the turbine exhaust nozzle 140. The core duct 142 is an annular duct positioned generally inside the core shroud 122 in the radial direction R. The core duct 142 (e.g., the working gas flow path through the turbine 120) may be referred to as a second stream.

[0028] Fan section 150 includes fan 152, which is the main fan in this example embodiment. Figure 1 In the illustrated embodiment, the fan 152 is an open rotor or non-ducted fan 152. As shown, the fan 152 includes an array of fan blades 154. The fan blades 154 are rotatable, for example, about the longitudinal axis 112. Figure 1 , the fan 152 is drivingly coupled to the low pressure turbine 134 via the LP shaft 138. The fan 152 may be coupled directly to the LP shaft 138, for example, in a direct drive configuration. Figure 1 In the illustrated embodiment, the fan 152 is coupled to the LP shaft 138 via a reduction gearbox 155 , for example, in an indirect drive or gear drive configuration.

[0029] Furthermore, fan blades 154 can be arranged equally spaced about longitudinal axis 112. Each fan blade 154 has a root and a tip and a span defined therebetween. Each fan blade 154 defines a central blade axis 156. For this embodiment, each fan blade 154 of fan 152 is capable of rotating about its respective central blade axis 156, e.g., rotating in unison with one another. One or more actuators 158 are provided to facilitate such rotation and, therefore, can be used to change the pitch of fan blades 154 about their respective central blade axis 156.

[0030] The fan section 150 also includes a fan guide vane array 160 including fan guide vanes 162 ( Figure 1 For this embodiment, the fan guide vanes 162 are not rotatable about the longitudinal axis 112. Each fan guide vane 162 has a root and a tip and a span defined therebetween. The fan guide vanes 162 may be as follows: Figure 1 It is shown unobstructed or, alternatively, may be obstructed, for example, by an annular shroud spaced outwardly in the radial direction R from the tips of the fan guide vanes 162 or attached to the fan guide vanes 162 .

[0031] Each fan guide vane 162 defines a central blade axis 164. For this embodiment, each fan guide vane 162 of the fan guide vane array 160 is capable of rotating about its respective central blade axis 164, e.g., rotating in unison with one another. One or more actuators 166 are provided to facilitate such rotation and, thus, can be used to change the pitch of the fan guide vanes 162 about their respective central blade axis 164. However, in other embodiments, each fan guide vane 162 may be fixed or unable to pitch about its central blade axis 164. The fan guide vanes 162 are mounted to a fan housing 170.

[0032] like Figure 1 As shown, in addition to the unducted fan 152, a ducted fan 184 is also included behind the fan 152, so that the gas turbine engine 100 includes both ducted and unducted fans, both of which are used to generate thrust by the movement of air that does not pass through at least a portion of the turbine 120 (e.g., the HP compressor 128 and the combustion section in the illustrated embodiment). The ducted fan 184 can be located at approximately the same axial position as the fan blades 154 or the vanes 162, and radially inward of the fan blades 154 or the vanes 162. For the illustrated embodiment, the ducted fan 184 is driven by the low-pressure turbine 134 (e.g., coupled to the LP shaft 138).

[0033] Fan shroud 170 annularly surrounds at least a portion of core shroud 122 and is generally positioned outboard of at least a portion of core shroud 122 in radial direction R. Specifically, a downstream section of fan shroud 170 extends over a forward portion of core shroud 122 to define a fan flow path or fan duct 172. Fan flow path or fan duct 172 may be referred to as a tertiary flow of gas turbine engine 100.

[0034] Incoming air may enter the fan duct 172 through the fan duct inlet 176 and may be discharged through the fan exhaust nozzle 178 to generate propulsive thrust. The fan duct 172 is an annular duct that is generally positioned outboard of the core duct 142 in the radial direction R. The fan shroud 170 and the core shroud 122 are connected together and are supported by a plurality of substantially radially extending, circumferentially spaced stationary struts 174 ( Figure 1 The fan duct 172 and the core duct 142 may be supported by the fan duct 170 and the core duct 142 (only one shown). The stationary struts 174 may each have an aerodynamic profile to guide the air flowing therethrough. In addition to the stationary struts 174, other struts may also be used to connect and support the fan shroud 170 and / or the core shroud 122. In many embodiments, the fan duct 172 and the core duct 142 may at least partially extend together (typically axially) on opposite sides (e.g., opposite radial sides) of the core shroud 122. For example, the fan duct 172 and the core duct 142 may each extend directly from the leading edge 144 of the core shroud 122 and may partially extend together, typically axially, on opposite radial sides of the core shroud.

[0035] Gas turbine engine 100 further defines or includes an inlet duct 180. Inlet duct 180 extends between an engine inlet 182 and core inlet 124 / fan duct inlet 176. Engine inlet 182 is generally defined at the forward end of fan casing 170 and is positioned between fan 152 and fan guide vane array 160 in axial direction A. Inlet duct 180 is an annular duct positioned inboard of fan casing 170 in radial direction R. Air flowing downstream along inlet duct 180 is divided (but not necessarily evenly) by flow splitter or leading edge 144 of core casing 122 into core duct 142 and fan duct 172. Inlet duct 180 is wider in radial direction R than core duct 142. Inlet duct 180 is also wider in radial direction R than fan duct 172.

[0036] Next reference Figure 2 , a block diagram of an embodiment of the engine 100 is shown. The engine 100 includes an engine controller 210 configured to receive input from a time of flight (TOF) sensor 250 and control the position of one or more effectors 265 via effector actuators 260. In some embodiments, the engine controller 210 includes a processor and one or more memory storage devices storing executable code that causes the processor to perform the operations described herein. Figure 3 One or more steps described. The engine controller 210 may be configured to send a control signal to the effector actuator 260 based on the effector position determined based on the signal from the TOF sensor 250. In some embodiments, the engine controller 210 is a processor-based control system for the engine, such as a full authority digital engine control ("FADEC") of the engine 100. In some embodiments, the engine controller 210 may include effector control circuitry separate from the FADEC and / or an effector control software module executed by the FADEC. In some embodiments, the engine controller 210 is configured to change the position of the effector 265 in response to a signal from an aircraft controller (e.g., a throttle) and / or based on a predetermined schedule. In some embodiments, to change the effector 265 to a selected position, the engine controller 210 may gradually increase or decrease the angle of the effector 265 via the effector actuator 260 until the sensor 250 senses that the effector 265 is in the selected position. It is noted that Figure 2 This is a simplified block diagram only, and the engine controller 210 may also be configured to control other engine components.

[0037] The effector actuator 260 is an engine component that physically changes the position of the effector 265. In some embodiments, the effector actuator 260 includes components for converting electrical power into motion of the effector 265 based on signals received from the engine controller 210. In some embodiments, the effector 265 may include a variable geometry device having a geometry (e.g., pitch) that can be physically manipulated by the effector actuator 260 to affect thrust or airflow of the engine 100. In some embodiments, the effector actuator 260 includes a blade pitch actuator, a stator vane actuator, an inlet guide vane pitch actuator, an outlet guide vane pitch actuator, a bleed valve actuator, or a variable nozzle actuator. In some embodiments, the effector actuator 260 is coupled to a rotating fan blade of the engine, such as with reference to FIG. Figure 1 In some embodiments, the effector actuator 260 is coupled to a stationary blade of the engine, such as the fan blade 154 of FIG. Figure 1 In some embodiments, the effector actuator 260 may be a reference to the fan guide vanes 162. Figure 1 The actuator 158 or the actuator 166 described above. In some embodiments, the effector 265 may include one or more of variable pitch blades, variable stator vanes, inlet guide vanes, outlet guide vanes, a discharge valve, a variable nozzle, and the like.

[0038] Effector actuator 260 may include one or more static portions and one or more movable elements. Typically, the static portion remains in the same position relative to the housing of effector actuator 260 and / or engine 100. For example, the static portion may include a portion of the housing of effector actuator 260 and / or a mounting member coupled to the housing. The movable element may typically be an element that moves relative to the static portion as effector 265 is actuated. In some embodiments, the movable element is a linear motion component of the effector actuator. For example, the movable element may be a piston rod, crank arm, or rod that linearly displaces as the effector position changes. In some embodiments, in addition to linear displacement, the movable element also rotates within the housing of the effector actuator. For example, the movable element may be a portion of actuator 158 that is coupled to and rotates with the rotating fan blades of fan 152.

[0039] The TOF sensor 250 is typically positioned to measure the distance from the TOF sensor 250 to a reflective surface within the effector actuator 260. The TOF sensor 250 is configured to emit an energy wave (e.g., ultrasonic wave) through a medium (e.g., a working fluid) toward a reflective surface and measure the time it takes for the wave to travel to the reflective surface and back to the sensor. The travel time is then converted to a distance based on a known or calibrated speed of the wave through the medium. In some embodiments, the TOF sensor 250 is an ultrasonic ranging sensor, such as a MEMS (micro-electromechanical system) PMUT (piezoelectric micro-machined ultrasonic transducer) sensor. In some embodiments, the TOF sensor 250 may include other types of ranging sensors, such as optical, laser, acoustic, and / or electromagnetic TOF sensors.

[0040] In some embodiments, the TOF sensor 250 is mounted on a movable element of the effector actuator 260, and the reflective surface is a surface of a static portion of the effector actuator 260. For example, in Figure 4A , a piston 400 representing the effector actuator 260 is shown. The piston 400 includes a cylinder 410 and a piston rod 420. The cylinder 410 encloses a cavity 430 filled with a working fluid (e.g., fluid oil, gas, air, water, or an oil-based solution, etc.) and is coupled to a motion mechanism 415 to affect the position of the effector 265. Figure 4A In the embodiment shown, the sensor 250A is mounted on the movable piston rod 420 and the reflective surface 255A is a static surface of the cylinder 410 .

[0041] In some embodiments, the TOF sensor 250 is mounted on a static portion of the effector actuator 260, and the reflective surface is a surface of a movable element of the effector actuator 260. For example, Figure 4BAs shown, the sensor 250B may be mounted on the cylinder 410 of the piston 400 , and the reflective surface 255B may be part of the piston rod 420 .

[0042] In some embodiments, the engine 100 further includes a calibration mechanism for calibrating the distance measurement of the TOF sensor 250 to account for variations in the speed at which waves travel through the working fluid at different temperatures, pressures, and aeration levels. The calibration mechanism may include a calibration surface and / or a second calibration TOF sensor. In some embodiments, the calibration mechanism may include an operating condition sensor and a software algorithm. Figure 3 、 Figure 5A and Figure 5B Further details of an example calibration mechanism are described.

[0043] Next reference Figure 3 , shows a method 300 for engine effector position measurement and control. In some embodiments, Figure 3 One or more steps in are performed using a processor-based control system of the engine (eg, engine controller 210 of engine 100 ).

[0044] In step 320, the distance between the TOF sensor 250 within the housing of the effector actuator 260 and the reflective surface is measured. The TOF sensor 250 may be an ultrasonic distance sensor, such as a MEMS PMUT sensor. In some embodiments, the TOF sensor 250 may be another type of sensor capable of measuring distance through a medium. In some embodiments, the distance is measured based on TOF = 2*L / C, where L represents length and C represents the speed of sound in the medium.

[0045] In some applications of the described systems and methods, the medium through which the TOF sensor 250 measures distance is comprised of a primary medium having an oil temperature between -40°F and 300°F and a pressure of up to approximately 2000 psia. In some embodiments, the oil temperature may be as high as 320°F or 350°F. Under ambient conditions, the speed of sound in the working fluid may be approximately 1,450 m / s. However, the speed of sound may vary by up to 30% based on operating conditions (e.g., temperature, pressure, aeration, etc.). The actuator stroke may be 0.5 to 7.0 inches (1.27 to 17.78 cm), in which case the total distance traveled by the TOF sensor wave is twice the stroke, approximately 1 to 14 inches (2.54 to 35.56 cm). The TOF of the sensor wave from the sensor to the reflecting surface and back may be 17.5 to 242.5 microseconds. In some embodiments, the TOF may be between 12.2 µs and 314.4 µs with a tolerance of up to 30%. The carrier frequency range can be 1 to 10 megahertz (MHz). In some embodiments, the carrier frequency range can be 1 to 20 MHz. In some embodiments, the carrier frequency range can be selected based on the medium and the length to be measured to improve resolution / accuracy and reduce attenuation. In some embodiments, the engine controller 210 may include a circuit device capable of calculating TOF with a resolution of 1 microsecond (us) to obtain an accuracy of approximately 0.75 mm in oil. For a six-inch (15.24 cm) stroke actuation, due to resolution reasons, such a processor can provide an accuracy of approximately 0.5%. For a seven-inch (17.78 cm) stroke actuation, such a processor can provide an accuracy of approximately 0.4%. In some embodiments, the field of view (FoV) of TOF may be 5° or less because the position of the reflective surface is known and aligned with the sensor.

[0046] In some embodiments, in step 310, calibration is performed. In some embodiments, calibration can be based on determining the speed of the wave passing through the medium. As described above, the operating conditions of the effector actuator 260 can affect the speed of the wave passing through the working fluid of the effector actuator 260. In order to obtain accurate distance measurement, the engine controller 210 can calibrate the measured TOF in step 310. In some embodiments, the speed can be determined via the operating conditions of the effector actuator 260. For example, the engine 100 and / or the effector actuator 260 may include one or more sensors for measuring operating conditions (e.g., temperature, pressure, aeration, etc.). The measured operating conditions can be used to determine the speed of the sensor wave in the medium. The distance is then calculated based on the TOF measured by the effector actuator 260 and the speed determined under the measured conditions. In some embodiments, the measured operating conditions can be used to determine the speed of the wave in the medium based on an equation or a lookup table.

[0047] In some embodiments, calibration can be performed based on calibration measurements performed within effector actuator 260. In some embodiments, calibration measurements can be performed simultaneously with the distance measurements in step 320. In some embodiments, calibration measurements can be performed at a lower, the same, or a higher frequency than the distance measurements in step 320. In some embodiments, as Figure 5A As shown, effector actuator 260 includes a separate calibration sensor 510 positioned at a known distance Lc from calibration surface 515. Calibration sensor 510 can be a second TOF sensor. Calibration surface 515 can be an existing static part of effector actuator 260 or a surface specifically added to effector actuator 260 for calibration. For example, calibration surface 515 can be coupled to calibration sensor 510 at a fixed distance. Engine controller 210 can use the travel time (TOFc) measured by calibration sensor 510 and the known distance (Lc) to calibration surface 515 to determine the speed (C) of the wave through the medium under current operating conditions based on TOFc=2*Lc / C. For example, if calibration sensor 510, positioned 4 cm from calibration surface 515, measures a TOFc of 1 ms, it can be determined that the C of the medium under current operating conditions is 0.0125 s / m. The speed of the wave through the medium can then be used to determine the distance L between TOF sensor 250 and the reflective surface 255 being measured. For example, when the TOF sensor 250 measures a TOF of 2 ms under the same operating conditions, L may be determined according to TOF / 2 / 0.125 s / m=8 cm.

[0048] In other embodiments, Figure 5B As shown, the effector actuator 260 can include a calibration surface 515a, rather than a separate calibration sensor, that is configured to reflect a portion of the wave emitted by the TOF sensor 250 while allowing the remaining wave to pass through to the reflective surface 255 to be measured. The calibration surface 515a can be, for example, a low-density or mixed-density solid. In this configuration, the velocity (C) of the wave through the medium can be similarly derived based on the known Lc to the calibration surface 515a to calibrate the distance L measurement.

[0049] In step 330, the engine controller 210 determines the effector position based on the distance measured in step 320. In some embodiments, the engine controller 210 may store an equation or lookup table for converting the measured distance to the reflective surface (e.g., centimeters) to the effector position (e.g., pitch angle).

[0050] In step 340, the engine controller 210 sends a signal to change the effector position based at least in part on the effector position determined in step 330. For example, the engine controller 210 may compare the measured position with a target position determined based on an engine schedule and / or flight control inputs. The engine controller 210 may actuate the effector 265 open or closed to match the target position based on the measured effector position. In some embodiments, the engine controller 210 may incrementally instruct the effector actuator 260 to modify the position of the effector 265 until the measured effector position reaches the target position. In some embodiments, the engine controller 210 may use the measured effector position to confirm successful actuation of the effector 265 and, if the target effector position cannot be achieved, generate an alarm or modify the control of other effectors.

[0051] use Figure 2 The system shown and Figure 3 The illustrated process provides a compact sensor system within the effector actuator 260, which reduces the overall sensor envelope and improves sensor reliability. The sensor system can also self-calibrate / compensate to maintain distance measurement accuracy under different operating conditions.

[0052] Further aspects of the present disclosure are provided by the subject matter of the following clauses:

[0053] A system for measuring the position of an effector of an engine, the system comprising: an effector actuator of an engine, the effector actuator comprising a housing and one or more movable elements for changing the effector position of an effector coupled to the effector actuator; and a time-of-flight (TOF) sensor within the housing of the effector actuator and positioned to measure the distance between the TOF sensor and a reflective surface within the housing to determine the effector position of the effector.

[0054] A system as in any preceding clause, wherein the TOF sensor is mounted on a static part of the effector actuator and the reflective surface is a surface of a movable element.

[0055] A system as in any preceding clause, wherein the TOF sensor is mounted on a movable element and the reflective surface is a surface of a static part of the effector actuator.

[0056] The system of any preceding clause, wherein the effector actuator comprises a blade pitch actuator, a stator vane actuator, an inlet guide vane pitch actuator, an outlet guide vane pitch actuator, a discharge valve actuator, or a variable nozzle actuator.

[0057] The system of any preceding clause, wherein the one or more movable elements comprise a linear motion component of the effector actuator.

[0058] A system as in any preceding clause, wherein the TOF sensor comprises an ultrasonic sensor.

[0059] A system according to any preceding clause, further comprising a calibration sensor comprising a second TOF sensor and a calibration surface at a known distance from the second TOF sensor, wherein the distance is measured based on calibrating the travel time measured by the TOF sensor based on a calibration travel time measured by the calibration sensor.

[0060] A system as in any preceding clause, further comprising a calibration surface at a known distance from the TOF sensor, and wherein the distance is measured based on calibrating a travel time associated with the reflective surface based on a calibration travel time associated with the calibration surface.

[0061] A system as in any preceding clause, wherein the calibration surface is configured to reflect a portion of waves emitted by the TOF sensor while allowing the remaining waves to pass through to the reflective surface.

[0062] The system of any preceding clause, wherein the TOF sensor is positioned inside a cavity filled with a working fluid of the effector actuator.

[0063] A system as in any preceding clause, wherein the one or more movable elements comprises a piston that is linearly displaced as a function of the position of the effector.

[0064] The system of any preceding clause, wherein the effector actuator is coupled to a rotating fan blade of the engine.

[0065] The system of any preceding clause, wherein the effector actuator is coupled to a stationary blade of the engine.

[0066] The system of any preceding clause, wherein the reflective surface rotates within the housing of the effector actuator.

[0067] A method for measuring the position of an engine effector, the method comprising: measuring, using a time-of-flight (TOF) sensor within a housing of an effector actuator of the engine, a distance between the TOF sensor and a reflective surface within the housing, wherein the effector actuator comprises a static portion and one or more movable elements for changing an effector position of an effector coupled to the effector actuator; and determining, using a processor, the effector position of the effector based on the distance measured by the TOF sensor; and controlling the effector actuator by the processor based on the effector position.

[0068] The method of any preceding clause, wherein the effector actuators include blade pitch actuators, stator vane actuators, inlet guide vane pitch actuators, outlet guide vane pitch actuators, discharge valve actuators, and variable nozzle actuators.

[0069] A method as described in any preceding clause, wherein the distance is measured based on calibrating the travel time measured by the TOF sensor based on a calibration travel time measured by a calibration sensor, wherein the calibration sensor includes a second TOF sensor and a calibration surface at a known distance from the second TOF sensor.

[0070] A method according to any preceding clause, further wherein the distance is measured based on calibrating a travel time associated with the reflecting surface using a speed at which waves travel through a medium, the speed at which waves travel through the medium being determined based on a calibrated travel time associated with a calibration surface at a known distance from the TOF sensor.

[0071] A method as in any preceding clause, wherein the calibration surface is configured to reflect a portion of waves emitted by the TOF sensor while allowing the remaining waves to pass through to the reflective surface.

[0072] A method as in any preceding clause, wherein the TOF sensor is positioned inside a cavity filled with a working fluid of the effector actuator.

[0073] A system for measuring an effector position of an engine, the system comprising: a time-of-flight (TOF) sensor within a housing of an effector actuator of the engine, the effector actuator comprising a static portion and one or more movable elements for changing an effector position of an effector coupled to the effector actuator, wherein the TOF sensor is positioned to measure a distance between the TOF sensor and a reflective surface within the housing; and a processor configured to determine the effector position of the effector based on the distance measured by the TOF sensor.

[0074] A system as in any of the preceding clauses, wherein the TOF sensor is mounted on the static part of the effector actuator and the reflective surface is a surface of a movable element.

[0075] A system as in any of the preceding clauses, wherein the TOF sensor is mounted on a movable element of the effector actuator and the reflective surface is a surface of the static part.

[0076] The system of any of the preceding clauses, wherein the effector actuator comprises a blade pitch actuator, a stator vane actuator, an inlet guide vane pitch actuator, an outlet guide vane pitch actuator, a discharge valve actuator, or a variable nozzle actuator.

[0077] The system of any of the preceding clauses, wherein the one or more movable elements comprise a linear motion component of the effector actuator.

[0078] A system as claimed in any preceding clause, wherein the TOF sensor comprises an ultrasonic sensor.

[0079] The system of any of the preceding clauses further comprising a calibration sensor comprising a second TOF sensor and a calibration surface at a known distance from the second TOF sensor, wherein the distance is measured based on calibrating the travel time measured by the TOF sensor based on a calibration travel time measured by the calibration sensor.

[0080] A system as in any of the preceding clauses, further comprising a calibration surface at a known distance from the TOF sensor, and wherein the distance is measured based on calibrating a travel time associated with the reflective surface based on a calibration travel time associated with the calibration surface.

[0081] A system as claimed in any preceding clause, wherein the calibration surface is configured to reflect a portion of the waves emitted by the TOF sensor while allowing the remaining waves to pass through to the reflecting surface.

[0082] The system of any of the preceding clauses, wherein the TOF sensor is positioned inside a cavity filled with a working fluid of the effector actuator.

[0083] A system as in any preceding clause, wherein the one or more movable elements comprises a piston that is linearly displaced as the position of the effector changes.

[0084] The system of any of the preceding clauses, wherein the effector actuator is coupled to a rotating fan blade of the engine.

[0085] The system of any of the preceding clauses, wherein the effector actuator is coupled to a stationary blade of the engine.

[0086] The system of any of the preceding clauses, wherein the reflective surface rotates within the housing of the effector actuator.

[0087] A method for measuring an effector position of an engine, the method comprising: measuring, using a time-of-flight (TOF) sensor within a housing of an effector actuator of the engine, a distance between the TOF sensor and a reflective surface within the housing, wherein the effector actuator comprises a static portion and one or more movable elements for changing an effector position of an effector coupled to the effector actuator; and determining, using a processor, the effector position of the effector based on the distance measured by the TOF sensor.

[0088] A method as in any of the preceding clauses, wherein the TOF sensor is mounted on the static part of the effector actuator and the reflective surface is a surface of a movable element.

[0089] A method as in any of the preceding clauses, wherein the TOF sensor is mounted on a movable element of the effector actuator and the reflective surface is a surface of the static part.

[0090] The method of any of the preceding clauses, wherein the effector actuators include blade pitch actuators, stator vane actuators, inlet guide vane pitch actuators, outlet guide vane pitch actuators, discharge valve actuators, and variable nozzle actuators.

[0091] The method of any of the preceding clauses, wherein the one or more movable elements comprise a linear motion component of the effector actuator.

[0092] A method as in any preceding clause, wherein the TOF sensor comprises an ultrasonic sensor.

[0093] A method according to any of the preceding clauses, wherein the distance is measured based on calibrating the travel time measured by the TOF sensor based on a calibration travel time measured by the calibration sensor, wherein the calibration sensor comprises a second TOF sensor and a calibration surface at a known distance from the second TOF sensor.

[0094] A method as in any preceding clause, further wherein the distance is measured based on calibrating a travel time associated with the reflective surface based on a calibrated travel time associated with a calibration surface at a known distance from the TOF sensor.

[0095] A method as in any preceding clause, wherein the calibration surface is configured to reflect a portion of the waves emitted by the TOF sensor while allowing the remaining waves to pass to the reflecting surface.

[0096] The method of any of the preceding clauses, wherein the TOF sensor is positioned inside a cavity filled with a working fluid of the effector actuator.

[0097] A method as in any preceding clause, wherein the one or more movable elements comprises a piston that is linearly displaced as the position of the effector changes.

[0098] The method of any preceding clause, wherein the effector actuator is coupled to a rotating fan blade of the engine.

[0099] The method of any of the preceding clauses, wherein the effector actuator is coupled to a stationary blade of the engine.

[0100] A method as in any preceding clause, wherein the reflective surface rotates within the housing of the effector actuator.

[0101] This written description uses examples to disclose the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A system for measuring the position of an engine effector, characterized in that: The system comprises: an effector actuator of an engine, the effector actuator comprising a housing and one or more movable elements for changing an effector position of an effector coupled to the effector actuator; and A time of flight (TOF) sensor is within a housing of the effector actuator and is positioned to measure a distance between the TOF sensor and a reflective surface within the housing to determine the effector position of the effector.

2. The system according to claim 1, wherein: in, The TOF sensor is mounted on a static part of the effector actuator and the reflective surface is a surface of a movable element.

3. The system according to claim 1, wherein: in, The TOF sensor is mounted on a movable element and the reflective surface is a surface of a static part of the effector actuator.

4. The system according to claim 1, wherein: in, The effector actuator includes a blade pitch actuator, a stator vane actuator, an inlet guide vane pitch actuator, an outlet guide vane pitch actuator, a discharge valve actuator, or a variable nozzle actuator.

5. The system according to claim 1, wherein: in, The one or more movable elements comprise a linear motion component of the effector actuator.

6. The system according to claim 1, wherein: in, The TOF sensor includes an ultrasonic sensor.

7. The system according to claim 1, wherein: Further included is a calibration sensor comprising a second TOF sensor and a calibration surface at a known distance from the second TOF sensor, wherein the distance is measured based on calibrating the travel time measured by the TOF sensor based on a calibration travel time measured by the calibration sensor.

8. The system according to claim 1, wherein: Further comprising a calibration surface at a known distance from the TOF sensor, and wherein the distance is measured based on calibrating a travel time associated with the reflective surface based on a calibration travel time associated with the calibration surface.

9. The system according to claim 8, characterized in that in, The calibration surface is configured to reflect a portion of the waves emitted by the TOF sensor while allowing the remaining waves to pass through to the reflecting surface.

10. The system according to claim 1, wherein: in, The TOF sensor is positioned inside a cavity filled with a working fluid of the effector actuator.

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