Self-Powered Fluid Metering Unit for Aircraft Fuel Control
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Solution Overview
Problem
Aircraft gas turbine engine combustors require high-pressure fuel delivery, necessitating multiple fuel nozzles and complex wiring for individual fuel flow control, which increases cost, weight, space requirements, and reliability concerns due to the extensive use of power supplies and interconnections.
Innovation Solution
A self-contained fluid metering module that generates power from the fluid flow using an electric machine with a rotating component, allowing for closed-loop control of fuel flow through a microcontroller, reducing the need for external power sources and minimizing wiring by using wireless communication and power generation capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional power supplies and wiring are used to power each metering unit, then individual fuel flow control is achieved, but system complexity, weight, and cost increase
Solution Approach 1:
The metering unit operates autonomously by generating its own power from the fuel flow through a micro-turbine engine, eliminating the need for external power supplies and extensive wiring. The unit serves itself by converting the kinetic energy of the passing fuel into mechanical power to drive its control mechanisms.
Solution Approach 2:
The power generation capability is extracted and integrated directly into each metering unit, removing the need for separate power supply systems and reducing the overall system complexity. Each unit becomes self-sufficient by incorporating its own power generation mechanism.
2Ease of operation
If traditional power supplies are used for each metering unit, then fuel flow control is maintained, but weight and space requirements increase
Solution Approach 1:
The metering unit generates its own power from the fuel flow, eliminating the need for heavy external power supplies. The micro-turbine engine converts the kinetic energy of the passing fuel into mechanical power, making the system lightweight and self-sufficient.
Solution Approach 2:
The traditional electrical power supply system is replaced with a mechanical power generation system that directly converts fuel flow energy into mechanical work, eliminating the need for heavy electrical infrastructure.
3Ease of operation
If extensive wiring and power supplies are used, then individual metering control is achieved, but reliability decreases
Solution Approach 1:
Each metering unit operates independently with self-generated power, eliminating numerous interconnections and potential failure points. The autonomous operation reduces reliance on external power supplies and complex wiring, thereby improving overall system reliability.
Solution Approach 2:
The system is divided into independent, self-sufficient metering units that operate autonomously. This segmentation reduces the impact of failures in one unit on others and eliminates the need for extensive interconnections, improving reliability.
4Stress or pressure
If multiple fuel nozzles are used to deliver high-pressure fuel, then combustor requirements are met, but system complexity and cost increase
Solution Approach 1:
Each metering unit is designed as a multi-functional component that combines fuel pressure regulation, flow metering, and individual flow control capabilities. This universal design reduces the need for separate specialized components for each function.
Solution Approach 2:
The metering units autonomously regulate and control fuel flow without requiring external control systems, reducing overall system complexity while maintaining the ability to meet combustor pressure and flow requirements.
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 solution enables efficient, individually controlled fuel flow to each nozzle, optimizing engine performance while reducing system complexity, weight, and cost by eliminating the need for extensive wiring and external power supplies, thereby enhancing reliability and reducing hardware complexity.
Implementation Method 1
an electric machine that generates power from the fluid flow
Implementation Method 2
a rotating component that generates power from the fluid flow
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A system (10) includes a metering module (12a) that receives fluid through a fluid inlet and includes a rotating component (28a) driven by the fluid, an electric machine (30a), and a controller (32a). The fluid is received from the fluid inlet at an inlet flow rate, and the rotating component (28a) provides the fluid to an outlet of the rotating component (28a) at an outlet pressure. The electric machine (30a) is configured to generate electrical power in response to rotation of the rotating component (28a). The controller (32a) is powered by the electrical power generated by the electric machine (30a), and controls a rotational speed of the rotating component (28a) to control the outlet pressure.