Distributed Engine Control Architecture for Harsh-Environment I/O
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Solution Overview
Problem
Control systems for gas turbine engines face challenges such as harsh operating environments, high data throughput requirements, rapid processor obsolescence, and cyber security threats, which limit their design flexibility, processing power, and reliability.
Innovation Solution
A distributed control system architecture is implemented, where a low-power I/O module operates within the harsh engine environment and a higher-processing-power computation module is located in a benign external environment, connected via a network interface, allowing for efficient data communication and processing, and incorporating cyber security measures through a fiber optic data network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If control systems use high-processing-power processors to handle future data throughput requirements, then processing capability is improved, but the system becomes vulnerable to harsh operating environments and requires costly redesign due to rapid obsolescence
Solution Approach 1:
The control system is divided into two separate modules: a hardened I/O module that interfaces with the harsh engine environment and a separate computation module that can use high-processing-power processors in a protected environment. This segmentation allows each module to be optimized for its specific requirements without compromise.
Solution Approach 2:
A communication interface acts as an intermediary between the hardened I/O module and the high-performance computation module. This intermediary enables data exchange while isolating the vulnerable high-processing-power processor from the harsh operating environment, allowing it to maintain reliability while providing enhanced processing capability.
2Manufacturing precision
If control systems are tightly integrated with interconnected components to minimize connection lengths, then signal integrity is improved, but design flexibility and adaptability are reduced
Solution Approach 1:
The system is segmented into modular components (I/O module and computation module) that can be independently designed, manufactured, and configured. This modularity maintains signal integrity within each module while providing flexibility in system integration and deployment configurations.
Solution Approach 2:
The standardized communication interface between modules provides universal connectivity that supports multiple configuration options and platform adaptations. This universal interface enables the same modular components to be used across different applications and platforms, significantly enhancing design flexibility and adaptability.
3Reliability
If control systems use bespoke customized designs for specific purposes, then performance for specific applications is improved, but lifecycle costs and development time are increased
Solution Approach 1:
The control system is segmented into standardized modular components that can be reused across multiple applications. The I/O module and computation module can be independently developed and then configured for specific applications through software rather than hardware customization, reducing lifecycle costs while maintaining application-specific performance.
Solution Approach 2:
The system allows for parameter changes and configuration adjustments through software programming rather than hardware redesign. This enables the same physical hardware platform to be adapted for different applications by changing operational parameters and software configurations, significantly reducing development time and lifecycle costs compared to bespoke hardware designs.
Data Source
AI summary
Control systems and methods for controlling an engine. The control system includes a computation module and an input/output (I/O) module attached to the engine. The computation module is located in an area of the engine, or off-engine, that provides a more benign environment than the environment that the I/O module is subject to during operation of the engine. The I/O module includes a first processor and a first network interface device. The computation module includes a second processor with higher processing power than the first processor, and a second network interface device. The control system also includes a sensor configured to provide sensor readings to the first processor. The first processor transmits data based on the sensor readings to the second processor. The control system also includes an actuator operably coupled to the I/O module and that is controlled by the first processor based on commands from the second processor.