Built-In Test Control Modules for Fault-Tolerant Turbomachinery Loops
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Solution Overview
Problem
Distributed control systems in turbomachines face challenges in maintaining control and efficiency due to isolated failures of distributed control modules, which can lead to reduced performance or render the turbomachine inoperable, and a fault in the main processing unit can impact the entire network.
Innovation Solution
Incorporating a built-in test module within distributed control modules to determine fault states and respond with appropriate control commands, such as closed-loop, augmented closed-loop, or disconnect commands, to preserve control of controllable components even in fault conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If distributed control modules are used to localize control commands, then system reliability is improved by isolating failures to individual modules, but control may be lost when a module fails
Solution Approach 1:
The control module performs self-diagnostics and detects fault conditions before they result in complete control loss. By continuously monitoring its own operational status and predicting potential failures, the system can take preventive actions to maintain control continuity.
Solution Approach 2:
A fault management intermediary layer is introduced between the control module and the controllable component. This intermediary processes fault conditions and determines appropriate responses, such as switching to backup control paths or adjusting control parameters, thereby maintaining control continuity during faults.
2Reliability
If isolated fault containment is implemented in distributed control modules, then failure impact is limited to individual modules, but control capability is reduced when faults occur
Solution Approach 1:
The control module dynamically adjusts its operational mode based on detected fault conditions. When faults are detected, the system transitions from normal operation to fault-tolerant modes, modifying control strategies to maintain essential functionality while containing the fault impact.
Solution Approach 2:
Control parameters are dynamically changed in response to fault conditions. The system modifies control gains, thresholds, or operational limits to accommodate degraded performance while maintaining stable control of the controllable component during fault states.
3Difficulty of detecting and measuring
If built-in test modules are added to detect fault states, then fault detection capability is improved, but device complexity increases
Solution Approach 1:
The built-in test module is merged with the existing control module architecture, sharing processing resources and communication infrastructure. This integration approach enables comprehensive fault detection capabilities while minimizing the increase in overall device complexity through resource sharing.
Solution Approach 2:
The control module is designed with multi-functionality, serving both as the primary control unit and as a self-diagnostics system. By making the control module universal, the patent eliminates the need for separate dedicated test equipment, thereby improving fault detection capability without proportionally increasing device complexity.
4Ease of operation
If multiple control command types are implemented for different fault states, then control preservation is improved, but control system complexity increases
Solution Approach 1:
The control command structure is segmented into distinct types (normal control commands, fault-tolerant control commands, and emergency control commands). This segmentation allows the system to select appropriate command types based on fault severity, improving control preservation while managing complexity through structured categorization.
Solution Approach 2:
Instead of having a single complex control command that handles all scenarios, the system uses multiple specialized control command types, each optimized for specific fault conditions. This inversion of the design approach simplifies the control logic for each command type while collectively providing comprehensive fault coverage.
Data Source
AI summary
A distributed control system having at least a distributed control module is disclosed. The distributed control module may be configured to determine a fault state associated with a control loop using a built-in test module. The built-in test module may be incorporated into the distributed control module. The fault state may include no faults, a communication fault, a sensor operation fault, or a controllable component fault. The distributed control module may be configured to transmit a closed-loop control command from the distributed control module to a controllable component when the fault state comprises no faults, or transmit an augmented control command from the distributed control module to the controllable component when the fault state comprises a communication fault or a sensor operation fault, or transmit a disconnect control command from the distributed control module to a controllable component when the fault state comprises a controllable component fault.