Pitch Actuator Torque Sensing for Turbine Propeller Whirl Detection

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Solution Overview

Problem

Turbine engines experience propeller whirl, causing fan blades to rotate off-center and altering the angle of attack, which affects engine performance, and existing systems lack effective methods to detect this phenomenon.

Innovation Solution

A sensor system comprising accelerometers, load cells, strain gauges, and pressure sensors is used to measure holding torque on fan blades to detect propeller whirl, providing real-time data for whirl detection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If fan blades rotate at high speed in a turbine engine, then power output increases, but propeller whirl occurs causing the blades to rotate off-center and alter angle of attack

Engineering Contradiction:

Improvepower outputVSAvoidblade rotational stability

Core Design Contradiction:

PowerVSStability of the object's composition

Solution Approach 1:

The sensor assembly detects propeller whirl conditions before they cause severe performance degradation. By monitoring holding torque variations in real-time and comparing them against threshold values, the system can identify early signs of propeller whirl and trigger corrective actions or warnings before the condition worsens

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors holding torque through the sensor assembly and provides real-time feedback about propeller whirl conditions. The controller compares detected torque variations with predetermined thresholds and can trigger alerts or corrective measures, creating a closed-loop feedback system that maintains blade stability

Inventive Principle:

Principle #23Feedback

2Reliability

If existing detection systems are used, then system complexity is low, but propeller whirl cannot be effectively detected

Engineering Contradiction:

Improvewhirl detection accuracyVSAvoidsensor system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sensor assembly acts as an intermediary device that indirectly measures propeller whirl conditions by detecting holding torque variations. Instead of directly observing blade position or whirl motion, the system uses torque sensors coupled to the pitch actuator to detect the effects of propeller whirl, simplifying the measurement approach while maintaining detection reliability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces complex mechanical measurement devices with electrical sensors. Instead of using mechanical position sensors or vibration sensors that would require direct contact with rotating blades, the invention uses electrical torque sensors that measure holding torque through the pitch actuator mechanism, substituting a simpler electrical measurement system for a complex mechanical one

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Difficulty of detecting and measuring

If sensor assembly is added to detect propeller whirl, then detection capability improves, but device complexity increases

Engineering Contradiction:

Improveholding torque measurement capabilityVSAvoidoverall system complexity

Core Design Contradiction:

Difficulty of detecting and measuringVSDevice complexity

Solution Approach 1:

The sensor assembly serves multiple functions: it detects holding torque variations, identifies propeller whirl conditions, and provides data for both monitoring and control purposes. By making the sensor system multi-functional, the patent reduces the need for separate detection systems for different parameters, thereby limiting the increase in overall device complexity

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

The sensor system effectively monitors propeller whirl by measuring changes in holding torque, enabling early detection and potential mitigation of performance-affecting blade oscillations.

Implementation Method 1

A sensor system comprising accelerometers, load cells, strain gauges, and pressure sensors is used to measure holding torque on fan blades

Methodology Applied

Scientific EffectStrain gauge measurement:

Data Source

PatentUS20260036084A1Sensor assembly to detect propeller whirl in a turbine engine

Publication Date: 2026.02.05 GENERAL ELECTRIC CO

AI summary

A turbine engine includes a plurality of fan blades configured to rotate about a longitudinal centerline axis of the turbine engine, a pitch actuator configured to control a pitch angle of each of the plurality of fan blades, a sensor assembly configured to detect a holding torque of the plurality of fan blades, and a controller configured to monitor propeller whirl in the plurality of fan blades by detecting the holding torque. The sensor assembly includes a first sensor coupled to the pitch actuator and configured to detect the holding torque of all of the plurality of fan blades and a second sensor coupled to the pitch actuator and configured to detect the holding torque of at least one fan blade of the plurality of fan blades. The pitch actuator is configured to take a corrective action when propeller whirl is detected outside of a predetermined limit.