Distributed Gas Turbine Engine Control via Wireless Communication

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Solution Overview

Problem

Current federated aircraft engine control systems are large, heavy, and complex due to centralized Electronic Engine Controllers (EECs) and long wiring harnesses, which are costly to redesign and maintain, and hinder easy component maintenance and aesthetics.

Innovation Solution

A distributed electrical system for gas turbine engines using a permanent magnet alternator driven by a gearbox to power docking stations, with wireless communication between the electronic engine control and components, reducing the need for hard-wired connections and simplifying the system architecture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a centralized Electronic Engine Controller (EEC) is used to control all engine and airframe connections, then control functionality is integrated and reliable, but the system size, weight, and complexity increase significantly

Engineering Contradiction:

Improvecontrol functionalityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The centralized EEC is divided into multiple distributed control modules, each responsible for specific engine parameters or subsystems. These modules are distributed throughout the engine structure, eliminating the need for a single large controller while maintaining control reliability through modular architecture.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control architecture transitions from a single-point centralized control to a multi-point distributed control network. This dimensional shift from 1D (single controller) to 3D (spatially distributed modules) reduces complexity by spreading functionality across the engine volume rather than concentrating it in one location.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Adaptability or versatility

If long wiring harnesses are used to connect the fan case EEC to engine core components, then all connections are provided, but weight increases and maintenance becomes difficult

Engineering Contradiction:

Improveconnection capabilityVSAvoidmaintenance accessibility

Core Design Contradiction:

Adaptability or versatilityVSEase of repair

Solution Approach 1:

The extensive wiring harness is extracted and replaced with wireless communication technology. Control modules communicate with sensors and actuators through wireless signals, eliminating the physical wiring infrastructure that caused weight and maintenance issues while preserving full connection capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical wiring system is replaced with an electromagnetic wireless communication system. This substitution eliminates the need for physical wire harnesses, connectors, and routing infrastructure, dramatically reducing weight and simplifying maintenance while maintaining communication functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If a centralized EEC with all connections is used, then control coverage is complete, but the system is heavy and limits external packaging

Engineering Contradiction:

Improvecontrol coverageVSAvoidsystem weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

The heavy mechanical wiring harness infrastructure is replaced with lightweight wireless communication systems. This substitution maintains complete control coverage across all engine components while dramatically reducing the weight of the electrical system, thereby increasing available payload capacity and improving overall engine performance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If extensive wiring harnesses are used for engine connections, then all components are connected, but durability concerns arise and aesthetics are compromised

Engineering Contradiction:

Improvecomponent connectivityVSAvoidwiring durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The vulnerable mechanical wiring harness is replaced with a wireless communication system that has no physical connections subject to wear, vibration, or environmental damage. This substitution maintains full component connectivity while eliminating durability concerns associated with extensive wiring in harsh engine environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution reduces the size, weight, and complexity of the engine control system, enhances maintenance accessibility, and improves durability by eliminating the need for extensive wiring harnesses and dedicated I/O ports, while maintaining reliable communication across the engine components.

Implementation Method 1

the power source is a permanent magnet alternator driven by a gearbox

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3088707B1Distributed electrical architecture of a gas turbine engine and method of operation

Publication Date: 2020.08.05 RTX CORP

Figure 1
Figure 2

AI summary

A distributed electrical system (50) includes a plurality of engine components (54) each in electrical communication with one of a plurality of docking stations (60). An electronic engine control (52) is positioned remote from the engine components (54) and is configured to communicate wirelessly with each of the plurality of engine components (54).