Compact Modular Fuel Control Module for Jet Engines
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Solution Overview
Problem
Existing fuel delivery systems for gas turbine engines are complex, costly, and space-consuming due to multiple separate components, and struggle with high pressure and contamination issues, particularly in jet engine applications where sustained high pressure and accurate fuel metering are required.
Innovation Solution
A compact, modular fuel control system integrating a motor-driven pump, filter, flow divider, and shut-off section within a single housing, featuring a double-ended spool piston pump and pressure-activated flow divider, with a filter bypass and pressure sensor for efficient operation and minimal leakage, capable of handling high pressures and contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (fuel pump, pressure accumulator, fuel metering device) are used in the fuel delivery system, then the system can meet the requirements for damping pulsation and accurate fuel metering, but the system becomes expensive and occupies excessive space
Solution Approach 1:
The patent combines the fuel pump, pressure accumulator, and fuel metering device into a single integrated unit. The pump housing contains both the pumping mechanism and the metering mechanism, eliminating the need for separate components and reducing system complexity while maintaining the functional requirements for pulsation damping and accurate fuel metering.
Solution Approach 2:
The integrated fuel pump and metering device performs multiple functions simultaneously: it pumps fuel, dampens pulsation, and meters fuel delivery. This multi-functional design eliminates the need for separate dedicated components for each function, reducing the overall number of parts while maintaining system reliability.
2Productivity
If gear pumps are used to create pressure differential by moving fuel through intermeshing teeth, then the pump can handle high flow rates, but the pump consumes excessive power and experiences internal leakage
Solution Approach 1:
The patent replaces the traditional gear pump mechanical system with a diaphragm-based pumping mechanism actuated by a cam and follower system. This substitution eliminates the intermeshing teeth design that causes internal leakage and high power consumption, while maintaining the ability to deliver high fuel flow rates through the diaphragm's reciprocating motion.
3Device complexity
If the fuel pump and metering device are combined into one unit, then the system occupies less space and costs less, but the combined device must meet extreme pump and metering requirements simultaneously
Solution Approach 1:
The integrated device is segmented into distinct functional zones: the pump section with diaphragm and cam mechanism for fuel delivery, and the metering section with adjustable metering means for precise flow control. This segmentation allows each section to be optimized for its specific function while working together as a compact integrated unit, meeting both extreme pump and metering requirements.
4Reliability
If rolling diaphragms are used to pump and meter fuel, then contaminants can be kept from degrading working components, but the diaphragms have pressure limitations that reduce suitability for sustained high pressure applications
Solution Approach 1:
The patent employs diaphragms constructed from composite materials or specially engineered elastomers that combine the contaminant exclusion properties of rolling diaphragms with enhanced pressure resistance. These advanced materials allow the diaphragm to withstand sustained high pressures (over 500 psi) while maintaining its ability to keep contaminants from degrading working components.
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
The system provides accurate, non-pulsed fuel flow with low leakage and high turn-down ratio, suitable for jet engines, reducing space and weight while maintaining efficiency and reliability, and simplifying installation and maintenance.
Implementation Method 1
the pump section has a spool piston reciprocated by the motor in response to a signal from the motor drive to effect flow of fuel between housing inlet and outlet ports
Implementation Method 2
The filter element is a toroidal pleated wire mesh, preferably rated 10 μm nominal and 25 μm absolute
Implementation Method 3
a filter pressure differential sensor that provides a signal to a master computer or other user interface
Data Source
AI summary
A fuel control system is provided in a single compact modular unit. The unit includes a motor driving a highly accurate cam-operated double-acting piston metering pump, both of which are contained in a liquid fuel environment. As the liquid fuel is pumped it works to cool internal components including the motor. An electronic motor drive is contained in a dry chamber of the unit for controlling operation of the motor and pump and is cooled indirectly by the fuel as well. A pressure sensitive flow divider is also included for selectively providing one or multiple output fuel flow paths depending upon whether a pressure threshold is reached, for example to send fuel to primary and secondary burner nozzles. Filter, filter bypass, pressure relief, and fuel shut-off components are also integrated into the single modular unit.