Turbine Shaft Torque Sensing with Redundant Strain Sensors
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Solution Overview
Problem
Current torque measurement systems for gas turbine engines face challenges in accuracy due to reliance on rotational readings alone, failure to account for thermal strain, and single signal path vulnerabilities, leading to unreliable and maintenance-intensive measurements.
Innovation Solution
A system with redundant sensor modules and signal paths, including a static antenna with multiple bands for secure signal transmission, provides accurate and reliable torque measurements by compensating for thermal strain and ensuring continuous data availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If rotational readings alone are used to estimate shaft strain, then the system complexity is reduced, but measurement precision deteriorates due to loss of thermal strain information
Solution Approach 1:
The system segments the measurement function by separating rotational sensing (via reluctance sensor) from strain sensing (via strain gauge), with each sensor handling a specific aspect of shaft behavior. This allows comprehensive torque measurement while maintaining manageable system complexity through functional decomposition.
Solution Approach 2:
A processor acts as an intermediary that receives both rotational readings and strain measurements, then combines these data streams to calculate accurate torque values. The processor mediates between the two sensor types, integrating their information to resolve the contradiction between simple rotational sensing and precise strain measurement.
2Device complexity
If a single signal path is used for strain detection, then device complexity is reduced, but reliability deteriorates due to vulnerability to interruption
Solution Approach 1:
The system implements local quality by providing redundancy specifically for the signal transmission function. Multiple independent signal paths are created between the strain gauge and processor, ensuring that if one path fails, another can maintain measurement reliability without requiring complete system duplication.
Solution Approach 2:
The system prepares for potential signal path failures by establishing redundant communication channels in advance. This prior cushioning ensures that measurement reliability is maintained even when interruptions occur, as alternative signal paths are already in place to carry measurement data.
3Productivity
If strain-based sensing systems operate long term without recalibration, then productivity is improved, but measurement precision deteriorates due to drift and reliability issues
Solution Approach 1:
The system incorporates feedback mechanisms where the processor continuously monitors strain gauge signals and compares them against expected values based on rotational measurements and torque models. This feedback loop detects drift conditions and can trigger recalibration or compensation, maintaining measurement precision over long operational periods without frequent manual intervention.
Solution Approach 2:
The system performs self-calibration and self-diagnosis functions, where the processor uses the relationship between rotational readings and strain measurements to automatically compensate for drift. This self-service capability maintains measurement precision over time without requiring external recalibration, improving productivity by reducing maintenance frequency.
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 achieves accurate and reliable torque measurements, reducing maintenance needs and providing real-time updates on engine component life and performance, thereby enhancing engine health monitoring and operational efficiency.
Implementation Method 1
The sensor module can include a Wheatstone bridge circuit including a strain sensor disposed on the shaft
Implementation Method 2
The static antenna can include a first band and a second band. The first band can be in operable communication with the first sensor module... The second band can be in operable communication with the second sensor module...
Data Source
AI summary
A gas turbine engine and system for measuring torque for a gas turbine engine shaft is provided. The system may include a first sensor module, a second sensor module, a first coupler, a second coupler, and a static antenna. The first and second sensor modules may include strain sensors positioned on the gas turbine engine shaft. The first coupler may be positioned on the gas turbine engine shaft and electrically connected with the first sensor module. The second coupler may be positioned on the gas turbine engine shaft and electrically connected with the second sensor module. The static antenna may include a first band and a second band. The first signal band may be in operable communication with the first sensor module and positioned radially outward from the first coupler. The second signal band may be in operable communication with the second sensor module and positioned radially outward from the second coupler.