Gas Turbine Shaft Failure Detection via Speed Signal Continuity
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Solution Overview
Problem
Gas turbine engines face challenges in detecting shaft failures quickly and accurately to prevent uncontained turbine component fragmentation, which can lead to serious damage and safety risks, as existing systems rely on heavy containment rings and complex electrical circuits prone to false detection.
Innovation Solution
A gas turbine engine system that utilizes an electrical compressor speed sensor with a built-in continuity circuit and a controller to detect simultaneous loss of speed and continuity signals, combined with pressure and surge data, to initiate a controlled shutdown only when all conditions are met, reducing the risk of false detection and eliminating the need for heavy containment rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid containment ring formed of high strength material is integrated into the outer engine housing to contain fragmented components, then the engine can contain high energy debris from turbine failure, but the engine weight increases significantly, sacrificing fuel economy and passenger capacity
Solution Approach 1:
The system performs preliminary detection of shaft failure conditions by monitoring compressor speed signal continuity and compressor outlet pressure. When a shaft failure is detected before turbine components fragment, the control system immediately shuts down the engine, preventing the need for containment structures. This proactive approach eliminates the weight penalty of containment rings while maintaining safety.
Solution Approach 2:
The invention extracts the containment function from the physical containment ring structure and replaces it with a detection-and-shutdown system. By removing the need for heavy containment structures through early fault detection and immediate engine shutdown, the system achieves the same safety objective without the associated weight penalty.
2Measurement precision
If complex electrical circuits are used for shaft failure detection, then the detection capability is improved, but the risk of false detection increases
Solution Approach 1:
The system uses feedback from multiple independent parameters (compressor speed signal continuity and compressor outlet pressure) to confirm shaft failure conditions. The control system monitors whether the compressor speed signal becomes discontinuous and whether the compressor outlet pressure remains above a threshold value, using this feedback loop to make accurate shutdown decisions and minimize false detections.
Solution Approach 2:
The invention uses existing multi-functional sensor systems (compressor speed sensors and pressure sensors) for their primary monitoring functions while also utilizing them for shaft failure detection. This multi-use approach improves reliability by cross-validating failure conditions through multiple sensor types rather than relying on a single specialized detection circuit.
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 effectively reduces the risk of false shaft failure detection and minimizes engine damage by ensuring accurate and timely shutdowns, enhancing safety and reducing the weight and complexity of the engine.
Implementation Method 1
an electrical compressor speed sensor located in front of the compressor (toward the compressor inlet). The speed sensor includes an electrical continuity circuit
Implementation Method 2
The controller includes an input for receiving the speed signal and the continuity signal, and is configured to generate a signal to shut down engine operation in response to a loss of both the speed signal and the continuity signal
Data Source
AI summary
A gas turbine engine is provided with a controller configured to detect a spool shaft failure and to initiate an engine shut-down in response to the shaft failure. The controller evaluates the compressor speed probe, the speed probe continuity, P30 pressure and compressor surge to determine whether a shaft failure has occurred.