Gas turbine engine fuel system prognostic algorithm

• US 10,287,986 B2
• Filed: 07/29/2016
• Issued: 05/14/2019
• Est. Priority Date: 07/29/2016
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Emmons, Floyd Richard, Salminen, David A.
• Primary Examiner(s): Barbee, Manuel L
• Application Number:
  US15/223,305
• Publication Number:
  US 20180030898A1
• Time in Patent Office: 1,019 Days
• CPC Class Codes: F02C 7/22 Fuel supply systems
• CPC Class Codes: F05D 2260/80 Diagnostics
• CPC Class Codes: F05D 2260/82 Forecasts
• CPC Class Codes: F05D 2260/821 Parameter estimation or prediction
• CPC Class Codes: G01M 15/14 Testing gas-turbine engines or jet-propulsion engines
• CPC Class Codes: G05B 23/0283 Predictive maintenance, e.g. involving the monitoring of a system and, based on the monitoring results, taking decisions on the maintenance schedule of the monitored system; Estimating remaining useful life [RUL] preventive maintenance, i.e. planning maintenance according to the available resources without monitoring the system G06Q10/06

Abstract

A system and method of calculating a fuel pump life expectancy in a fuel burning engine is provided. The method includes tracking a fuel pump speed of the fuel burning engine, tracking a position value of at least one fuel actuated actuator in the fuel burning engine, and calculating a fuel pump life expectancy value based on the fuel pump speed and the position value of the at least one fuel actuated actuator.

Claims

1. A method of calculating a fuel pump life expectancy in a fuel burning engine, the method comprising:

outputting fuel using a fuel pump operating at a fuel pump speed;

tracking the fuel pump speed of the fuel burning engine;

adjusting a position of the at least one fuel actuated actuator according to a baseline point of the fuel pump speed so as to reach a valve opening position within a valve adjustment time period;

tracking a position value indicating the position of at the least one fuel actuated actuator in the fuel burning engine;

delivering the fuel, via at least one fuel actuated actuator, to the fuel burning engine until the at least one fuel actuated actuator reaches a predetermined position;

changing the fuel pump speed to a second fuel pump speed as the fuel pump wears, thereby increasing the baseline point of the fuel pump and the valve adjustment time period;

calculating a fuel pump life expectancy value based on the fuel pump speed, the change in the valve adjustment time period, and the position value of the at least one fuel actuated actuator;

detecting when the fuel pump exceeds the fuel pump life expectancy in response to at least one of the baseline point and the valve adjustment time period exceeding a threshold value; and

replacing the fuel pump in response to the fuel pump exceeding the fuel pump life expectancy.

2. The method of claim 1, wherein the fuel actuated actuator is a stator vane.

3. The method of claim 2, wherein tracking the position value includes tracking a stator vane opening percentage.

4. The method of claim 3, wherein calculating the fuel pump life expectancy comprises:

determining a stator position point when the position value of the stator vane reaches a stator vane threshold position value during a fuel burning engine starting cycle.

5. The method of claim 1, wherein calculating the fuel pump life expectancy comprises:

detecting when the fuel pump speed reaches a speed threshold value.

6. The method of claim 1, further comprising:

tracking temperature values at different points and in different components of the system; and

adjusting the calculating of the fuel pump life expectancy value based on the tracked temperature values.

7. The method of claim 1, further comprising:

incorporating a time-history prognosticating algorithm to trend the fuel pump speed and position value of the at least one fuel actuated actuator over time; and

adjusting the calculating of the fuel pump life expectancy value based on the time-history prognosticating algorithm to determine a fuel pump replacement.

8. The method of claim 1, wherein tracking one or more of the following are inversely related to the fuel pump life expectancy:

an increase in time it takes the fuel actuated actuator to reach an open position;

an increase in time it takes for the fuel pump speed to reach a threshold; and

an increase in time when the fuel starts flowing.

9. The method of claim 1, further comprising:

compensating for fuel actuated actuator degradation by incorporating an algorithm to evaluate the performance of the fuel actuated actuator.

10. A computer program product for calculating a fuel pump life expectancy in a fuel burning engine, the computer program product comprising a non-transitory computer readable storage medium having program instructions embodied therewith, the program instructions executable by a processor to cause the processor to:

output fuel using a fuel pump operating at a fuel pump speed;

track a fuel pump speed of the fuel burning engine;

track a position value of at least one fuel actuated actuator in the fuel burning engine;

adjust a position of the at least one fuel actuated actuator according to a baseline point of the fuel pump speed so as to reach a valve opening position within a valve adjustment time period;

deliver the fuel, via at least one fuel actuated actuator, to the fuel burning engine when the at least one fuel actuated actuator reaches the open position;

change the fuel pump speed to a second fuel pump speed as the fuel pump wears, thereby increasing the baseline point of the fuel pump and the valve adjustment time period;

calculate a fuel pump life expectancy value based on the fuel pump speed, the change in the valve adjustment time period, and the position value of the at least one fuel actuated actuator;

detect when the fuel pump exceeds the fuel pump life expectancy in response to at least one of the baseline point and the valve adjustment time period exceeding a threshold value; and

replace the fuel pump in response to the fuel pump exceeding the fuel pump life expectancy.

11. The computer program product of claim 10, having additional program instructions embodied therewith, the additional program instructions executable by a processor to cause the processor to:

track a stator vane opening percentage, wherein the fuel actuated actuator is the stator vane.

12. The computer program product of claim 10, having additional program instructions embodied therewith, the additional program instructions executable by a processor to cause the processor to:

determine a stator position point when the position value of a stator vane reaches a stator vane threshold position value during a fuel burning engine starting cycle, wherein the fuel actuated actuator is the stator vane; and

detect when the fuel pump speed reaches a speed threshold value.

13. The computer program product of claim 10, having additional program instructions embodied therewith, the additional program instructions executable by a processor to cause the processor to:

track temperature values at different points and in different components of the system; and

adjust the calculating of the fuel pump life expectancy value based on the tracked temperature values.

14. The computer program product of claim 10, having additional program instructions embodied therewith, the additional program instructions executable by a processor to cause the processor to:

incorporate a time-history prognosticating algorithm to trend the fuel pump speed and position value of the at least one fuel actuated actuator over time; and

adjust the calculating of the fuel pump life expectancy value based on the time-history prognosticating algorithm to determine when a fuel pump replacement is required.

15. The computer program product of claim 10, wherein tracking one or more of the following are inversely related to the fuel pump life expectancy:

an increase in time it takes the fuel actuated actuator to reach an open position;

an increase in time it takes for the fuel pump speed to reach a threshold; and

an increase in time when the fuel starts flowing.

16. A system for determining a fuel pump life expectancy, the system comprising:

a fuel actuated actuator, wherein a fuel pump speed of the fuel burning engine is tracked and a position value of the fuel actuated actuator is tracked;

a fuel pump configured to provide fuel to the fuel burning engine; and

a controller configured to receive the fuel pump speed and the position value of the fuel actuated actuator and configured to calculate a fuel pump life expectancy value based on the fuel pump speed and the position value of the at least one fuel actuated actuator.

17. The system of claim 16,

wherein the fuel actuated actuator is a stator vane, and

wherein tracking the position value includes tracking a stator vane opening percentage.

18. The system of claim 17, further comprising:

a time-history prognosticating algorithm configured to trend the fuel pump speed and position value of the at least one fuel actuated actuator over time, wherein calculating the fuel pump life expectancy value is adjusting based on the time-history prognosticating algorithm to determine a fuel pump replacement.