Gas Turbine Distributed Control With Remote Computation Modules
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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 these demands effectively.
Innovation Solution
A distributed control system architecture for gas turbine engines, featuring a computation module and an I/O module with distinct processing units, where the computation module is located in a benign environment and the I/O module in a harsh environment, utilizing a high-bandwidth network for communication and employing software abstraction to manage functionality allocation and cybersecurity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If control systems use multiple I/O data connections to handle high data throughput rates, then data throughput capability is improved, but physical location constraints and system complexity increase due to harness length limitations
Solution Approach 1:
The patent replaces physical I/O data connections (mechanical/electrical harnesses) with wireless communication technology. This substitution eliminates the need for physical connection constraints while maintaining high data throughput capability, allowing control systems to handle future data rates without being limited by harness length or physical proximity requirements
Solution Approach 2:
The control system is divided into multiple independent functional modules (engine control module, airframe module, remote interface units) that can be physically separated and located optimally. Each module operates semi-independently, reducing the need for extensive physical interconnections and allowing distributed placement without increasing overall system complexity
2Reliability
If control systems are designed in a bespoke manner with customized components, then specific performance requirements are met, but manufacturing cost and development time increase
Solution Approach 1:
The patent employs universal, off-the-shelf components and standardized communication protocols that can be used across multiple control system applications. The modular architecture allows the same basic modules to be configured for different engine types and applications, reducing development costs and manufacturing complexity while maintaining optimized performance through software configuration rather than hardware customization
Solution Approach 2:
The system uses configurable software and programmable modules that can be dynamically adjusted to meet specific performance requirements without requiring custom hardware design. This allows the same physical platform to be adapted to different applications, reducing manufacturing costs while maintaining performance optimization
3Adaptability or versatility
If control systems use commercially available processors, then cost is reduced and adaptability is improved, but processor obsolescence and cybersecurity vulnerabilities increase
Solution Approach 1:
The control system separates critical safety functions from general control functions, placing them in different modules with different security requirements. This segmentation allows commercially available processors to be used in less critical areas while maintaining security and reliability in critical functions through architectural isolation and dedicated hardware where necessary
Solution Approach 2:
The patent introduces secure communication interfaces and authentication protocols as intermediaries between commercial processors and the control system. These intermediaries provide cybersecurity protection, allowing the use of commercially available processors while mitigating security vulnerabilities through layered defense mechanisms
4Device complexity
If control systems are located close to engine components, then connection length is minimized, but exposure to harsh environmental conditions increases
Solution Approach 1:
By replacing physical I/O connections with wireless communication, the system eliminates the trade-off between connection length and environmental exposure. Modules can be located remotely in environmentally benign areas while maintaining full communication capability, as wireless signals are not constrained by physical connection length limitations
Solution Approach 2:
Wireless communication signals act as intermediaries, allowing data transmission between remotely located control modules and engine components without requiring physical proximity. This enables modules to be positioned in protected environments while still functioning with components in harsh environments
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.