Gas Turbine Distributed Control Architecture for Harsh-Environment I/O
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Solution Overview
Problem
Current gas turbine engine control systems face challenges with high data throughput, harsh environmental conditions, rapid processor obsolescence, and cybersecurity requirements, necessitating a distributed control system architecture that can handle complex data processing and maintain reliability and security.
Innovation Solution
A distributed control system architecture for gas turbine engines, featuring a computation module and an input/output module with distinct processing units, where the computation module is located in a benign environment and the I/O module handles harsh conditions, utilizing a high-bandwidth network for communication and employing software abstraction to manage processor obsolescence and cybersecurity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If control systems are tightly integrated with other components through multiple I/O data connections, then data communication is achieved, but the control systems are constrained by physical location requirements and become highly customized
Solution Approach 1:
The control system is divided into multiple independent control modules, each capable of autonomous processing. This segmentation allows modules to be distributed physically while maintaining communication through a standardized data bus, eliminating the need for tight integration and custom harnesses between components.
Solution Approach 2:
A universal data bus is implemented that can carry multiple types of data traffic (sensor data, actuator commands, diagnostic information) between different control modules. This standardized interface replaces multiple dedicated connections, enabling flexible system configuration and reducing customization requirements.
2Productivity
If control systems handle high data throughput rates, then future data requirements are met, but processing power availability in hardened form is limited and processors become obsolete quickly
Solution Approach 1:
Processing functions are segmented and distributed across multiple control modules rather than concentrated in a single high-performance processor. Each module handles specific control tasks with appropriate processing power, eliminating the need for high-end hardened processors while maintaining overall system throughput through parallel processing.
Solution Approach 2:
The system architecture allows for dynamic allocation of processing tasks between modules and enables graceful degradation when individual modules or processors become obsolete. Software can be updated and reconfigured to utilize available processing resources, extending system lifecycle despite processor obsolescence.
3Reliability
If control systems are designed for specific purposes with customized components, then performance requirements are met, but lifecycle costs increase and flexibility decreases
Solution Approach 1:
Standardized control modules with universal interfaces and communication protocols are used throughout the system. These modules can be configured through software to meet different performance requirements, eliminating the need for custom-hardware design while maintaining required performance. This standardization significantly reduces manufacturing costs and lifecycle expenses.
Solution Approach 2:
System performance is adjusted through software configuration and parameter settings rather than hardware customization. Control modules can be reconfigured to meet different operational requirements by changing software parameters, enabling the same hardware platform to serve multiple purposes and reducing overall system cost.
4Reliability
If control systems require cyber security protection, then security requirements are met, but system complexity and implementation difficulty increase
Solution Approach 1:
The control system is segmented into modular units with defined communication interfaces. Cyber security measures can be implemented at each module boundary and within individual modules independently, making security management more tractable than in monolithic systems. Each module can have its own security credentials and access control lists.
Solution Approach 2:
A standardized data bus with built-in security protocols acts as an intermediary between control modules. This bus implements authentication, encryption, and message validation, providing cyber security protection without requiring complex security implementations in each individual module, thus reducing overall system complexity.
Data Source
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AI summary
Control systems and methods for controlling an engine. The control system (202, 300) includes a computation module (204, 306) 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, which 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 (210, 324); and a first network interface device (330). The computation module includes a second processor (208, 320) with higher processing power than the first processor, and a second network interface device (322). The control system also includes a sensor (318) 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 (316) operably coupled to the I/O module and that is controlled by the first processor based on commands from the second processor.