Propeller Overspeed Protection Logic Testing Automation

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Solution Overview

Problem

Current propeller overspeed protection systems in aircraft gas turbine engines require significant pilot involvement for testing, which is inefficient and increases pilot workload during pre-flight routines.

Innovation Solution

A system and method using speed and pitch angle sensors, processors, and controllers to automatically test propeller overspeed protection logic by overriding signals to simulate flight mode, modifying tripping points, and adjusting pitch angles to determine and address overspeed conditions, reducing pilot involvement and simplifying cockpit controls.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual testing of propeller overspeed protection system is implemented, then testing can be performed with existing simple controls, but pilot workload increases and testing efficiency decreases

Engineering Contradiction:

Improvepropeller overspeed protection testingVSAvoidpilot workload

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The controller automatically performs testing of the propeller overspeed protection system using existing sensors and control mechanisms, eliminating the need for manual pilot operation. The system self-tests by automatically overriding the ground mode signal and simulating flight conditions, thereby reducing pilot workload while maintaining testing reliability.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical testing operations with automated electronic control. The controller uses electronic signal overriding and automated data processing to substitute for manual pilot actions, instrument reading, and verification procedures, thereby improving ease of operation while maintaining testing effectiveness.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If automated testing is implemented, then pilot workload is reduced and testing efficiency improves, but system complexity increases

Engineering Contradiction:

Improvetesting efficiencyVSAvoidcontrol system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The controller acts as an intermediary between existing system components (sensors, actuators, flight mode logic) to coordinate automated testing. Rather than adding completely new complex systems, the controller mediates between existing elements, orchestrating their interaction to perform automated testing sequences, thereby improving productivity without proportionally increasing overall system complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The controller performs multiple functions: normal propeller control, flight mode management, and automated testing coordination. By making the controller universal and multi-functional, the patent avoids adding dedicated separate testing equipment, thereby improving testing efficiency while minimizing increases in device complexity through shared resources.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If ground mode signal is overridden to simulate flight mode, then automated testing of flight mode protection logic becomes possible, but signal integrity is compromised

Engineering Contradiction:

Improvetesting capabilityVSAvoidsignal accuracy

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system performs preliminary actions by temporarily overriding the ground mode signal only during designated testing sequences. This allows the system to simulate flight mode conditions and test protection logic before returning to normal operation. The overriding is done in advance of actual flight mode transitions, enabling controlled testing without compromising overall system reliability through proper timing and scope management.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The ground mode signal override occurs periodically during scheduled automated testing sequences rather than continuously. The system alternates between normal ground mode operation and temporary flight mode simulation for testing purposes. This periodic action allows adaptability for comprehensive testing while maintaining signal integrity during normal operations, as the override is time-limited and controlled.

Inventive Principle:

Principle #19Periodic action

Data Source

PatentUS11472575B2System and method for testing control logic for a propeller of a gas turbine engine

Publication Date: 2022.10.18 GE AVIO SRL

AI summary

A method (600) for testing control logic for a propeller driven by a gas turbine engine of an aircraft includes overriding (602) a signal indicating the aircraft is operating in a ground mode. The method can further include testing (604) minimum pitch protection logic when the signal is overridden; determining (606) the gas turbine engine is operating at a ground fine setting; restoring (608) the signal to an original state in which the signal indicates the aircraft is operating in the ground mode; modifying (610) pitch protection logic; determining (614) the propeller is operating at an overspeed condition; and testing (616) the propeller overspeed protection logic. In addition, the method can also determine (612) the propeller is operating at a low pitch condition when the gas turbine engine is operating at the ground fine setting.