Distributed Engine Control with Fiber-Optic Harsh-Zone 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 processor is located in the harsh environment of the gas turbine engine and a higher-power processor is positioned in a benign environment, connected via a network interface, allowing for efficient data communication and processing, while also incorporating cyber security measures through a fiber optic network.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If control systems are tightly integrated with interconnected components to minimize connection lengths, then reliability is improved, but device complexity increases and adaptability decreases
Solution Approach 1:
The control system is divided into multiple independent control modules, each capable of autonomous operation. These modules can be independently designed, tested, and replaced without affecting the entire system, thereby improving adaptability while maintaining reliability through modular redundancy.
Solution Approach 2:
A standardized interface layer is introduced between control modules and external components. This intermediary layer enables flexible reconfiguration and adaptation of system architecture without compromising the reliable connections between components, as the interface handles communication protocols and data formats.
2Productivity
If higher processing power processors are used to handle future data throughput requirements, then productivity is improved, but the system becomes more susceptible to obsolescence and cyber threats
Solution Approach 1:
Different processing capabilities are assigned to different control modules based on their specific functional requirements. Critical safety functions use robust, validated processors with proven longevity, while non-critical monitoring functions can utilize higher-performance processors for enhanced data throughput, optimizing the balance between productivity and reliability.
Solution Approach 2:
The patent replaces traditional high-power centralized processors with a distributed network of specialized processing units connected via fiber optic communication. This substitution eliminates the need for single high-performance processors that become obsolete, while maintaining high aggregate data throughput through parallel processing and optical communication bandwidth.
3Measurement precision
If multiple I/O data connections are used to link control systems with interconnected components, then measurement precision is improved, but device complexity increases
Solution Approach 1:
A universal communication bus architecture is implemented that allows multiple I/O connections to share common communication protocols and physical infrastructure. This enables precise data acquisition from multiple sensors and actuators while reducing overall system complexity through standardized interfaces and multiplexed communication channels.
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 architecture enhances processing power, reduces lifecycle costs, improves reliability, and addresses cyber security concerns by allowing for more flexible design, efficient data throughput, and reduced obsolescence, while maintaining engine safety and control functions.
Implementation Method 1
connected via a network interface, allowing for efficient data communication and processing, while also incorporating cyber security measures through a fiber optic network
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.