Isolated Speed Waveform Capture for Turbine Sensor Diagnostics
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Solution Overview
Problem
Industrial turbine and aircraft engine control systems face challenges in accurately sensing rotational speed due to variables affecting speed measurement accuracy, such as gear and speed wheel dimensions, cable parameters, and detection circuitry sensitivities, leading to difficulties in diagnosing and correcting speed sensor signal degradation before mechanical damage occurs.
Innovation Solution
A machinery speed control system that includes a speed sensor, detection circuitry, and measurement circuitry, which isolates data communication paths to prevent interference, allowing for waveform analysis, diagnostics, and control of the rotating machine. The system samples data with timestamps and includes a machine learning model to identify sensor faults and store threshold values, enabling advanced detection and correction of speed sensing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a variable reluctance sensor and gear are used to sense rotational speed, then speed feedback for turbine control is obtained, but signal degradation and measurement accuracy issues occur due to variables such as gear dimensions, cable parameters, and detection circuitry sensitivities
Solution Approach 1:
The patent divides the speed sensing system into separate functional modules: a speed sensor for generating waveforms, detection circuitry for processing signals, control circuitry for turbine operation, and measurement circuitry for waveform analysis. This segmentation allows each module to be optimized independently and facilitates diagnostic capabilities to identify signal degradation sources.
Solution Approach 2:
The patent introduces an intermediary measurement circuitry that captures and stores waveforms from the speed sensor independently of the control system. This intermediary component enables waveform analysis to diagnose signal quality issues without interfering with the primary control function, allowing detection of degradation before it affects turbine operation.
2Speed
If detection circuitry processes speed sensor signals for control operations, then real-time turbine control is achieved, but communication interference and diagnostic limitations occur
Solution Approach 1:
The patent separates the detection circuitry into two independent output paths: one for real-time control operations and another for waveform measurement and storage. This segmentation allows simultaneous real-time control and diagnostic waveform capture without interference, enabling both high-speed control response and comprehensive diagnostic capability.
Solution Approach 2:
The measurement circuitry creates a copy of the speed sensor waveforms for analysis purposes while the original signals continue to the control system. This copying approach enables diagnostic waveform storage and analysis without affecting the real-time control signal path, providing ease of diagnostics while maintaining real-time control performance.
3Reliability
If traditional speed sensing systems are used without waveform capture, then system simplicity is maintained, but early detection of sensor degradation and mechanical damage prevention is not possible
Solution Approach 1:
The patent implements preliminary waveform capture and storage capability that continuously monitors speed sensor signals and stores representative waveforms for later analysis. This preliminary action enables early detection of signal degradation trends before they cause mechanical damage, improving turbine reliability through preventive maintenance while adding only moderate system complexity.
Solution Approach 2:
The measurement circuitry provides self-diagnostic capability by automatically capturing, storing, and enabling analysis of speed sensor waveforms. This self-service approach allows the system to monitor its own health status and identify degradation issues without requiring external diagnostic equipment, improving reliability while keeping the added complexity manageable.
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 system provides accurate rotational speed measurement and recording, enabling advanced detection of speed sensing faults and correction of errors, thereby preventing mechanical damage and improving turbine operation reliability.
Implementation Method 1
The speed sensor is configured to measure a speed of a rotating machine
Implementation Method 2
The detection circuitry is in communication with and isolated from the speed sensor
Data Source
AI summary
The subject matter of this specification can be embodied in, among other things, a method for controlling a turbine engine that includes measuring, by a speed sensor, waveforms indicative of a speed of a rotating machine. Receiving the waveforms from the speed sensor and providing data representing the waveforms to a first signal path and to a second signal path, wherein the second signal path is isolated from the first signal path such that data communications at the second signal path do not interfere with communications on the first signal path. Controlling, responsive to the data received along the first signal path, one or more operations of the rotating machine. Storing, the data received along the second signal path, individual samples of the data in association with a respective timestamp indicating a time that the data was received.