Engine Control Input Simulation for N1/N2 Speed and Vibration

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Solution Overview

Problem

Developing and testing modern electronic engine control (EEC) systems for gas turbine engines requires actual gas turbine engine operation to generate speed and vibration signals, which is resource-intensive and wasteful.

Innovation Solution

A system comprising a first and second waveform generator to simulate N1 and N2 speed signals and a composite vibration signal, along with a voltage-to-charge converter to generate a simulated composite vibration charge signal, mimicking the output from an accelerometer, allowing for efficient simulation of inputs to the EEC system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If actual gas turbine engine operation is used to generate speed and vibration signals for EEC system testing, then the authenticity and reliability of test data is improved, but resource consumption and testing costs increase

Engineering Contradiction:
Improvetest data authenticityVSAvoidresource consumption
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The patent creates a virtual copy of the gas turbine engine system through a digital twin model that replicates engine behavior, speed signals, and vibration characteristics. This virtual model allows EEC system testing to be performed on copied data rather than requiring actual engine operation, thereby maintaining test authenticity while eliminating resource consumption associated with physical engine testing

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical physical engine system with a computational digital model. The digital twin uses software-based simulations to generate speed and vibration signals that substitute for physical sensor measurements, replacing the need for actual mechanical engine operation while preserving the functional characteristics needed for EEC testing

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If actual gas turbine engine operation is used for EEC system development and verification, then the accuracy of performance optimization is improved, but testing time and operational costs increase

Engineering Contradiction:
Improveperformance optimization accuracyVSAvoidtesting time
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

The patent prepares and validates the digital twin model in advance before actual EEC testing begins. The virtual model is pre-calibrated to accurately represent engine behavior across various operating conditions, allowing rapid iteration and testing of EEC algorithms without requiring repeated physical engine setups. This preliminary preparation enables fast, accurate testing while minimizing actual engine operation time

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The digital twin model dynamically adapts to simulate various engine operating conditions, speeds, and vibration scenarios on demand. This dynamic simulation capability allows the system to quickly change test parameters and scenarios without the physical constraints of actual engine operation, enabling comprehensive performance optimization testing in a fraction of the time required for physical testing

Inventive Principle:
Principle #15Dynamics

Data Source

PatentUS11474494B2Method for simulating an N1 and N2 speed vibration composite input for development and/or model based testing of engine control hardware and embedded software
Publication Date: 2022.10.18 HAMILTON SUNDSTRAND CORP
  • US11474494B2 patent drawing
  • US11474494B2 patent drawing
  • US11474494B2 patent drawing

AI summary

A system and method for generating input signals for an electronic engine control module includes a first waveform generator that is configured to generate a simulated first speed signal that is representative of a first speed and a vibration modulating signal that is representative of the first speed, a second waveform generator that is synchronized with the first waveform generator is configured to receive the vibration modulating signal and to generate a simulated second speed signal that is representative of a second speed and a simulated composite vibration voltage signal, and a voltage-to-charge converter that is configured to receive the simulated composite vibration voltage signal from the second waveform generator and to generate a simulated composite vibration charge signal that simulates a speed/vibration composite signal from an accelerometer.