High speed recorder for a gas turbine engine

• US 10,151,215 B2
• Filed: 05/31/2016
• Issued: 12/11/2018
• Est. Priority Date: 06/01/2015
• Status: Active Grant

• Current Assignee: Solar Turbines Incorporated (Caterpillar Incorporated)
• Original Assignee: Solar Turbines Incorporated (Caterpillar Incorporated)
• Inventors: Di Raimondo, Luvigi, Camboni, Roberto, Abbatiello, Gennaro
• Primary Examiner(s): Kuan, John
• Application Number:
  US15/169,417
• Publication Number:
  US 20160348532A1
• Time in Patent Office: 924 Days
• Field of Search: None
• CPC Class Codes: F01D 21/003 Arrangements for testing or measuring for measuring vibrations G01H
• CPC Class Codes: F05D 2220/32 in gas turbines
• CPC Class Codes: F05D 2260/80 Diagnostics
• CPC Class Codes: F05D 2270/304 Spool rotational speed
• CPC Class Codes: G01M 15/14 Testing gas-turbine engines or jet-propulsion engines
• CPC Class Codes: G05B 23/0221 Preprocessing measurements, e.g. data collection rate adjustment; Standardization of measurements; Time series or signal analysis, e.g. frequency analysis or wavelets; Trustworthiness of measurements; Indexes therefor; Measurements using easily measured parameters to estimate parameters difficult to measure; Virtual sensor creation; De-noising; Sensor fusion; Unconventional preprocessing inherently present in specific fault detection methods like PCA-based methods
• CPC Class Codes: G05B 23/0264 Control of logging system, e.g. decision on which data to store; time-stamping measurements

Abstract

A control system for a gas turbine engine is disclosed. In embodiments, control system includes a controller and a high speed recorder. The controller obtains sensor values from sensors connected to the gas turbine engine and publishes a map of trigger events. The high speed recorder reads the sensor values from the controller. The high speed recorder checks a map header for a change to the map header on a predetermined map reading interval, sets a flag when the map header has changed, and reads the map during the next loop of the map reading interval. The control system maintains timestamps assigned for the sensor values and to the trigger events on the same temporal axis.

Claims

1. A method of monitoring a high speed rotary machine, the high speed rotary machine having a control system including a controller and a high speed recorder, the method comprising:

the controller sampling sensors connected to the high speed rotary machine on a predetermined sensor sampling interval and monitoring the high speed rotary machine for trigger events;

the controller logging an array of sensor values obtained from the sensors and an occurrence of each trigger event including an event timestamp of when the trigger event occurred;

the controller updating a map on a predetermined map publishing interval, the map being updated to include the trigger events that have occurred within the last timeframe of the map publishing interval and a map header that is changed each time the map is updated;

the high speed recorder reading the sensor values obtained for each of the sensors from the controller on a predetermined sensor reading interval and checking the map header for a change to the map header on a predetermined map reading interval, the high speed recorder setting a flag when the map header has changed, and the high speed recorder reading the map during a next loop of the map reading interval, the map reading interval being shorter than the map publishing interval; and

the control system assigning timestamps on a same temporal axis by assigning a sensor timestamp to each sensor value on the same temporal axis as the event timestamps assigned by the controller.

2. The method of claim 1, wherein each sensor timestamp is assigned relative to a virtual time axis by subtracting a time on the virtual time axis that the sensor values were received at the high speed recorder by half of a difference between the time on the virtual time axis the sensor values were received at the high speed recorder and a time on the virtual time axis that a request to read the sensor values was sent by the high speed recorder.

3. The method of claim 1, wherein the high speed recorder reading the sensor values obtained for each of the sensors from the controller on the predetermined sensor reading interval includes correcting the predetermined sensor reading interval to account for latencies in an operating system.

4. The method of claim 3, wherein correcting the predetermined sensor reading interval to account for latencies in the operating system includes the high speed recorder maintaining an average cycle time between reading the sensor values over a predetermined number of cycles, increasing an actual predetermined sensor reading interval by a correction amount if the average cycle time is lower than a desired sensor reading interval by a predetermined amount, and decreasing the actual predetermined sensor reading interval by a correction amount if the average cycle time is higher than the desired sensor reading interval.

5. The method of claim 2, wherein:

the high speed recorder assigns a current value of the virtual time axis as a controller clock time plus a packet reading interval when date and time values for a controller clock are available; and

the high speed recorder performs a synchronization cycle at start-up of the high speed recorder and on a synchronization interval thereafter with the controller to establish the virtual time axis and the controller assigns a map timestamp in the map header to a current time of the virtual time axis by compensating for a delay of waiting until a next loop of the cycle for the map timestamp to be read when the date and time values for the controller clock are not available;

wherein the high speed recorder checking the map header for a change includes the high speed recorder checking the map timestamp.

6. The method of claim 5, wherein the map timestamp is a current time of the controller clock if the controller clock is available and is a synchronized time of the virtual time axis if the controller clock is not available.

7. The method of claim 6, wherein the map includes a Boolean value for each event to identify between two different states of the event, the event timestamp, and an offset that is a difference between the event timestamp and the map timestamp.

8. A method of monitoring a gas turbine engine, the gas turbine engine having a control system including a controller and a high speed recorder, the method comprising:

an operations controller of the controller sampling sensors connected to the gas turbine engine on a predetermined sensor sampling interval and monitoring the gas turbine engine for trigger events;

a map publisher of the controller logging an analog array including sensor values obtained from sampling the sensors and logging an event array, the event array including a Boolean value to identify between two different states of a trigger event and an event timestamp of when the trigger event occurred for each trigger event detected;

the map publisher updating a map on a predetermined map publishing interval of the trigger events that have occurred within the last cycle of the map publishing interval, the map including a map header with a map timestamp that is changed each time the map is updated;

an analog recorder of the high speed recorder reading the analog array from the map publisher on a predetermined sensor reading interval;

an event recorder of the high speed recorder checking the map header for a change to the map timestamp on a predetermined map reading interval, the event recorder setting a flag when the map timestamp has changed, and the event recorder reading the map during a next loop of the map reading interval, the map reading interval being shorter than the map publishing interval; and

the control system assigning a sensor timestamp to each sensor value read from the analog array by the analog recorder on a same temporal axis as the event timestamps.

9. The method of claim 8, wherein the analog recorder assigns each sensor timestamp relative to a virtual time axis by subtracting a time on the virtual time axis that the sensor value was received by the analog recorder by half of a difference between the time on the virtual time axis the sensor value was received by the analog recorder and a time on the virtual time axis that a request to read the analog array was sent by the analog recorder.

10. The method of claim 8, wherein the analog recorder reading the analog array on the predetermined sensor reading interval includes a frequency regulator of the high speed recorder correcting the predetermined sensor reading interval to account for latencies in an operating system.

11. The method of claim 10, wherein the frequency regulator correcting the predetermined sensor reading interval to account for latencies in the operating system includes the frequency regulator maintaining an average cycle time between reading the sensor values over a predetermined number of cycles, increasing an actual predetermined sensor reading interval by a correction amount if the average cycle time is lower than a desired sensor reading interval by a predetermined amount, and decreasing the actual predetermined sensor reading interval by a correction amount if the average cycle time is higher than the desired sensor reading interval.

12. The method of claim 8, assigning the sensor timestamps on the same temporal axis as the event timestamps includes:

a direct time offsetter of the high speed recorder assigning a current value of a virtual time axis as a controller clock time plus a packet reading interval when date and time values for a controller clock are available; and

a time inferencer of the high speed recorder performing a synchronization cycle at start-up of the high speed recorder and on a synchronization interval thereafter with the controller to establish the virtual time axis and the map publisher assigning the map timestamp in the map header to a current time of the virtual time axis by compensating for a delay of waiting until a next loop of the cycle for the map timestamp to be read when the date and time values for the controller clock are not available.

13. The method of claim 12, wherein the map timestamp is a time of the controller clock if the controller clock is available and is a synchronized time of the virtual time axis if the controller clock is not available.

14. The method of claim 8, further comprising:

a monitoring system obtaining sensor and event data timestamped on the same temporal axis from the high speed recorder; and

performing diagnostics on the gas turbine engine using the sensor and event data timestamped on the same temporal axis.

15. A control system for monitoring a high speed rotary machine, the control system comprising:

sensors connected to the high speed rotary machine;

a controller including one or more processors configured to

sample the sensors on a predetermined sensor sampling interval and to monitor the high speed rotary machine for trigger events, and

log an analog array including sensor values obtained from sampling the sensors, to log an event array, the event array including a Boolean value to identify between two different states of a trigger event and an event timestamp of when the trigger event occurred for each trigger event detected, and to publish a map on a predetermined map publishing interval of the trigger events that have occurred within the last cycle of the map publishing interval, the map including a map header with a map timestamp that is changed each time the map is published; and

a high speed recorder including

an analog recorder configured to read the analog array from the map publisher on a predetermined sensor reading interval, and

an event recorder configured to check the map header for a change to the map timestamp on a predetermined map reading interval, set a flag when the map timestamp has changed, and read the map during a next loop of the map reading interval, the map reading interval being shorter than the map publishing interval;

wherein the control system is configured to maintain timestamps on a same temporal axis by assigning a sensor timestamp to each sensor value read from the analog array by the analog recorder on the same temporal axis as the event timestamps.

16. The control system of claim 15, wherein the sensor timestamp for each sensor value is assigned by the analog recorder, and each sensor timestamp is assigned relative to a virtual time axis by subtracting a time on the virtual time axis that the sensor value was received by the analog recorder by half of a difference between the time on the virtual time axis the sensor value was received by the analog recorder and the time on a virtual time axis that a request to read the analog array was sent by the analog recorder.

17. The control system of claim 15, further comprising a frequency regulator configured to correct the predetermined sensor reading interval to account for latencies in an operating system.

18. The control system of claim 15, wherein the frequency regulator corrects the predetermined sensor reading interval to account for latencies in the operating system by maintaining an average cycle time between reading the sensor values over a predetermined number of cycles, increasing an actual predetermined sensor reading interval by a correction amount if the average cycle time is lower than a desired sensor reading interval by a predetermined amount, and decreasing the actual predetermined sensor reading interval by a correction amount if the average cycle time is higher than the desired sensor reading interval.

19. The control system of claim 15, further comprising:

a direct time offsetter that assigns a current value of a virtual time axis as a controller clock time plus a packet reading interval when date and time values for a controller clock are available; and

a time inferencer that performs a synchronization cycle at start-up of the high speed recorder and on a synchronization interval thereafter with the controller to establish the virtual time axis and the map publisher assigning the map timestamp in the map header to a current time of the virtual time axis by compensating for a delay of waiting until a next loop of the cycle for the map timestamp to be read when the date and time values for the controller are not available.

20. The control system of claim 19, wherein the map timestamp is a current time of the controller clock if the controller clock is available and is a synchronized time of the virtual time axis if the controller clock is not available.