Fuel Pump Life Prediction Using Speed and Actuator Position
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Solution Overview
Problem
Aircraft gas turbine engine fuel pumps experience internal leakage due to wear, leading to inefficient fuel delivery and premature replacement, as existing methods lack a practical way to assess pump performance and schedule maintenance optimally.
Innovation Solution
A method and system for calculating fuel pump life expectancy by tracking fuel pump speed and actuator position, incorporating temperature adjustments and time-history prognosticating algorithms to determine when replacement is necessary, allowing for on-condition maintenance rather than scheduled replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fuel pumps are replaced on a set schedule based on worst case scenario, then reliability is improved by preventing pump failure, but productivity deteriorates due to unnecessary replacements and increased maintenance costs
Solution Approach 1:
The patent changes the maintenance parameter from fixed time-based replacement to condition-based replacement using prognostic algorithms. The system monitors actual pump performance parameters (flow rate, pressure, power consumption) and predicts remaining useful life, allowing maintenance to be scheduled based on actual pump condition rather than predetermined time intervals, thus eliminating unnecessary replacements while ensuring reliability.
Solution Approach 2:
The patent implements a feedback mechanism where pump performance data is continuously monitored and fed back to the prognostic algorithm. The system measures actual pump output, compares it to expected performance, and adjusts the maintenance schedule based on the predicted degradation trend. This closed-loop feedback enables dynamic maintenance scheduling that adapts to actual pump condition, preventing both premature replacement and failure.
2Loss of information
If fuel pumps are monitored using pump speed detection methods, then measurement capability is improved, but measurement precision deteriorates because pump speed alone cannot accurately assess pump performance
Solution Approach 1:
The patent applies multi-functionality by using the fuel pump to serve dual purposes: both fuel delivery and self-diagnosis. The pump's own operational parameters (power consumption, rotational speed, fuel flow) are utilized to assess its health condition. This eliminates the need for separate monitoring systems while providing comprehensive performance information through the prognostic algorithm that analyzes multiple pump parameters simultaneously.
Solution Approach 2:
The patent introduces a prognostic algorithm as an intermediary between raw sensor data and maintenance decisions. The algorithm processes multiple parameters (power consumption, fuel flow, pressure) and translates them into a predicted remaining useful life. This intermediary layer synthesizes information from various sources to provide accurate pump condition assessment, overcoming the limitations of single-parameter monitoring.
3Device complexity
If internal leakage is allowed to increase with wear, then device complexity is reduced by not implementing continuous monitoring, but loss of substance increases due to fuel leakage
Solution Approach 1:
The patent implements self-service by enabling the fuel pump to monitor and assess its own condition using its inherent operational parameters. The prognostic algorithm uses data from the pump's own sensors (power consumption, rotational speed, fuel flow) to predict its health status. This self-diagnosis capability eliminates the need for complex external monitoring systems while enabling early detection of leakage issues, allowing timely intervention to prevent excessive fuel loss.
Data Source
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AI summary
A system and method of calculating a fuel pump life expectancy in a fuel burning engine is provided. The method includes tracking a fuel pump speed of the fuel burning engine (305), tracking a position value of at least one fuel actuated actuator in the fuel burning engine (310), and calculating a fuel pump life expectancy value based on the fuel pump speed and the position value of the at least one fuel actuated actuator (315).