Model-Based Torque Estimation for Gas Turbine Health Monitoring
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Solution Overview
Problem
Conventional engine models are inadequate for accurately modeling engine performance over time, particularly in gas turbine engines, as they fail to account for component efficiency degradation and higher-order thermodynamic and mechanical effects, limiting their operational effectiveness in real-time diagnostics and maintenance.
Innovation Solution
A model-based torque estimation system that uses a thermodynamic engine model based on component maps, coupled with a torque sensor and sensor compensation unit, to generate accurate torque estimates and health indicators, even in the event of torque sensor failure, and provides real-time data for enhanced engine diagnostics and power management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional engine models are used for fault detection and diagnostics, then the system complexity is reduced, but the measurement precision and reliability of engine performance modeling deteriorate due to inability to account for component efficiency degradation and higher-order thermodynamic effects
Solution Approach 1:
A physics-based thermodynamic model acts as an intermediary between raw engine sensor data and diagnostic conclusions. This model incorporates component efficiency degradation and higher-order thermodynamic effects to accurately predict engine performance parameters, enabling precise fault detection while maintaining manageable system complexity through structured modeling approaches
Solution Approach 2:
The system dynamically adjusts model parameters to reflect component efficiency degradation over time. By updating thermodynamic model parameters based on observed performance deviations and component wear patterns, the system maintains high measurement precision for engine performance modeling while using established thermodynamic relationships to control complexity
2Measurement precision
If a torque sensor is used to measure torque, then the measurement precision is improved, but the reliability deteriorates when the sensor fails, requiring a backup estimation system
Solution Approach 1:
A physics-based torque estimation system is implemented as a pre-prepared backup that can immediately take over when the torque sensor fails. This estimation model, based on thermodynamic relationships and component maps, provides a safety cushion that ensures continued reliable operation and monitoring even when the primary torque sensor becomes inoperative
Solution Approach 2:
The system continuously compares actual torque sensor measurements with model-based torque estimates to detect sensor failures. When deviations exceed thresholds indicating sensor malfunction, the system switches to using the model-based estimation, providing feedback-driven reliability enhancement that maintains accurate torque information throughout the engine's operational life
3Ease of operation
If real-time engine data is provided to the pilot, then the ease of operation is improved, but the loss of information increases due to the complexity of processing and transmitting multiple parameters
Solution Approach 1:
The system extracts and presents only the most critical engine health parameters and torque information to the pilot, rather than displaying all available sensor data. By selectively extracting key performance indicators and using physics-based models to synthesize comprehensive engine state information, the system improves pilot awareness while preventing information overload that could lead to processing errors
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
This solution enables improved engine operation and maintenance by providing accurate real-time data, enhancing flight safety, reducing maintenance costs, and allowing for timely detection of sensor failures and optimal maintenance scheduling.
Implementation Method 1
The engine includes a torque sensor configured to generate torque signals associated with torque within the engine
Implementation Method 2
The model-based torque estimation unit is configured to receive engine data associated with the engine and to generate torque estimation signals based on the engine data using a thermodynamic engine model
Data Source
AI summary
An operations support system for an engine includes a model-based torque estimation unit configured to receive engine data associated with the engine and to generate torque estimation signals based on the engine data using a thermodynamic engine model. The thermodynamic model is based on component maps associated with the engine.