High-Temperature Hub Unit Multiplexing Sensor Signals
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Solution Overview
Problem
Existing electronic systems for processing sensor data from gas turbine engines are limited by their temperature range, requiring extensive wiring and separate data transmission lines due to the inability of conventional electronics to operate effectively at high temperatures near the engines, leading to inefficiencies and increased maintenance efforts.
Innovation Solution
A hub unit with signal conditioning and control circuit boards adapted for high-temperature operation, capable of multiplexing analog sensor outputs and performing continuous calibration to remove errors caused by component aging and temperature drift, allowing data processing at a remote location without active cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional electronic components are used for data processing, then the system can operate at lower temperatures with standard components, but the electronics cannot withstand high temperatures near the engine core
Solution Approach 1:
The system is divided into two separate units: a hub unit positioned near the engine that can withstand high temperatures, and a remote data acquisition system located in a controlled environment. This segmentation allows each component to operate within its optimal temperature range, resolving the contradiction between high-temperature exposure and component reliability.
Solution Approach 2:
A specialized hub unit acts as an intermediary between the high-temperature engine environment and the temperature-sensitive remote data acquisition system. The hub unit receives sensor data directly from sensors near the engine core and transmits it to the remote system, shielding the conventional electronics from direct high-temperature exposure while maintaining data collection capabilities.
2Loss of information
If each sensor is connected to a remote data acquisition system with separate wires, then each sensor signal can be transmitted individually, but the number of wires and tubes required becomes very large
Solution Approach 1:
Multiple individual sensor connections are merged into a single communication channel. The hub unit aggregates data from multiple sensors and transmits it through one cable to the remote data acquisition system, eliminating the need for separate wires for each sensor while maintaining complete data transmission capability.
Solution Approach 2:
The single communication cable between the hub unit and remote system serves multiple functions: it carries data from multiple different sensors, provides power to the hub unit, and enables bidirectional communication. This multi-functionality replaces what would otherwise require multiple dedicated wires.
3Measurement precision
If sensors are placed close to the engine core to monitor high-temperature parameters, then accurate engine performance data can be obtained, but the sensors and electronics are exposed to temperatures exceeding their operating limits
Solution Approach 1:
The hub unit serves as a thermal intermediary, positioned in the high-temperature environment near the engine to receive sensor data, then transmitting this data to the remote system located in a cool, controlled environment. This allows precise monitoring of high-temperature parameters while protecting the electronics from thermal damage.
Solution Approach 2:
The monitoring system is segmented into a high-temperature tolerant hub unit that interfaces with sensors near the engine core, and a remote data acquisition system housed in a temperature-controlled facility. This spatial segmentation enables accurate measurement of high-temperature parameters while maintaining electronics within safe operating temperature ranges.
Data Source
AI summary
A hub unit adapted for use in a monitoring system that monitors engine performance parameters of a gas turbine engine. The hub unit includes a housing, at least one signal conditioning circuit board within the housing and adapted to receive the analog sensor outputs from the sensors, and a control circuit board within the housing, connected to the signal conditioning circuit board, and adapted to produce digital data corresponding to analog sensor outputs. The signal conditioning circuit board multiplexes a plurality of the analog sensor outputs generated by the sensors to produce an individual multiplexed analog output, and has at least one amplifier with adjustable gain for scaling the analog sensor outputs of the individual multiplexed analog output to produce an individual conditioned multiplexed analog output from which the corresponding digital data are produced. The amplifier and the adjustable gain thereof are controlled by the control circuit board.