Fuel Metering System for Heat Engine Zone Control

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Solution Overview

Problem

Existing multi-zone fuel metering systems for heat engines, such as gas turbine engines, face challenges with mechanical complexity, low accuracy control, increased pressure losses, and reduced flexibility due to series splitting methods, which lead to inefficiencies and stability issues like lean blowout and decreased thermal efficiency.

Innovation Solution

A fuel metering system with a main fuel line and zone fuel lines, equipped with pressure sensors and a servo-valve controlled fuel valve, uses a controller to determine and adjust the fuel valve actuator position and effective area based on pressure differences and compressor discharge pressure, enabling precise fuel flow management and reducing mechanical complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If series splitting of fuel is used downstream of a total flow meter, then fuel can be distributed to multiple zones, but pressure losses increase and dynamic pressure interactions cause system stability issues

Engineering Contradiction:

Improvefuel zone distribution capabilityVSAvoidpressure losses

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The fuel system is segmented into multiple parallel fuel lines, each with its own flow control valve and flow meter, allowing independent control of fuel flow to different zones without cascading valves that cause pressure losses

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces mechanical series-splitting valve arrangements with an electronic control system that uses electronic flow control valves and digital signal processing to manage fuel distribution, eliminating mechanical pressure interactions

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If series splitting of fuel is used downstream of a total flow meter, then fuel can be distributed to multiple zones, but control accuracy decreases due to cascading fuel valves

Engineering Contradiction:

Improvefuel zone distribution capabilityVSAvoidfuel flow control accuracy

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

Each fuel line is equipped with its own flow meter that provides real-time feedback to the controller, enabling precise control of fuel flow to each zone independently and compensating for variations in pressure and flow conditions

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces mechanical cascading valve arrangements with electronic flow control valves and digital signal processing, eliminating the cumulative errors and pressure interactions that degrade control accuracy in mechanical series-splitting systems

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If additional fuel zones are added to the engine, then combustion flexibility improves, but system weight, complexity, and control inefficiencies increase

Engineering Contradiction:

Improvecombustion flexibilityVSAvoidfuel metering system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The controller is designed as a multi-functional device that manages fuel flow to multiple zones through a unified electronic control architecture, consolidating control functions that would otherwise require separate mechanical systems for each zone

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent replaces multiple separate mechanical fuel metering systems with a single electronic control platform that manages all fuel zones through digital signal processing and electronic flow control, reducing mechanical complexity while maintaining or enhancing control capabilities

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Adaptability or versatility

If known fuel metering systems are scaled up to multiple fuel zones, then fuel distribution capability improves, but mechanical complexity increases significantly

Engineering Contradiction:

Improvefuel zone coverageVSAvoidmechanical complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical fuel metering systems with electronic flow control valves and digital signal processing, eliminating the need for multiple mechanical components and reducing overall system complexity while maintaining fuel distribution capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electronic controller serves as a universal management platform that handles fuel flow control for multiple zones through software algorithms, consolidating what would otherwise require separate mechanical control systems for each zone

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system improves fuel metering accuracy, reduces pressure drop, decreases fuel pump power requirements, enhances combustion dynamics, and increases thermal efficiency by allowing more flexible fueling and operation of multiple zones without increasing mechanical complexity.

Implementation Method 1

A first pressure sensor is disposed upstream of the fuel valve, in which the first pressure sensor is configured to obtain a first pressure value

Methodology Applied

Scientific EffectPressure sensing:

Implementation Method 2

A second pressure sensor is disposed downstream of the fuel valve, in which the second pressure sensor is configured to obtain a second pressure value

Methodology Applied

Scientific EffectPressure sensing:

Implementation Method 3

A flow meter is disposed downstream of the fuel valve

Methodology Applied

Scientific EffectFlow measurement:

Data Source

PatentEP3670874B1Fuel system for heat engine

Publication Date: 2023.04.26 GENERAL ELECTRIC CO

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AI summary

A fuel metering system (300) for a combustion section (26) of a turbo machine (10) is provided. The turbo machine (10) includes a main fuel line (301) configured to provide a flow of fuel and a zone fuel line (302) split from the main fuel line (301) through which at least a portion of the flow of fuel is provided. A fuel valve (320) is disposed at the zone fuel line (302) and is configured to obtain and receive a present fuel valve area value and a present valve position value. A first pressure sensor (315) is disposed upstream (99) of the fuel valve (320), in which the first pressure sensor (315) is configured to obtain a first pressure value. A second pressure sensor (325) is disposed downstream (98) of the fuel valve (320), in which the second pressure sensor (325) is configured to obtain a second pressure value. A flow meter (330) is disposed downstream (98) of the fuel valve (320). A controller (210) is configured to perform operations, in which the operations include determining a demanded fuel valve actuator position based at least on an estimated fuel valve actuator position and a demanded fuel flow (1056); comparing the demanded fuel flow and a present fuel flow (1040); determining an actual fuel valve actuator position based at least on the demanded fuel valve actuator position and the compared demanded fuel flow and present fuel flow; and generating an valve effective area at the fuel valve (320) (1060) based at least on the actual fuel valve actuator position.