Continuous performance analysis system and method

• US 8,068,997 B2
• Filed: 02/06/2009
• Issued: 11/29/2011
• Est. Priority Date: 02/06/2009
• Status: Active Grant

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Ling, Richard, Stramiello, Andy, Lee, Larry, Moeckly, Kevin, Goericke, Jan
• Primary Examiner(s): Schechter; Andrew
• Assistant Examiner(s): Huynh; Phuong
• Application Number:
  US12/367,182
• Publication Number:
  US 20100204931A1
• Time in Patent Office: 1,026 Days
• Field of Search: 702 41- 44, 702 72- 84, 702173-193
• US Class Current: 702/41
• CPC Class Codes: F05D 2220/329 in helicopters
• CPC Class Codes: F05D 2260/80 Diagnostics
• CPC Class Codes: G05B 23/0254 based on a quantitative model, e.g. mathematical relationships between inputs and outputs; functions: observer, Kalman filter, residual calculation, Neural Networks
• 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 conducting a continuous performance analysis for a system includes collecting transient performance data for a first parameter of the system and a second parameter of the system. Transfer functions are applied to the transient performance data for at least one of the first and second parameters to thereby generate phase compensated performance data representative of a steady state relationship between the first and second parameter. For each phase compensated performance datum, an estimate of the first parameter is calculated at a predetermined value of the second parameter using the phase compensated performance datum and a previously stored performance characteristic curve representative of the steady state relationship between the first and second parameters in a deterioration model extrapolation method. A very efficient binning method is used for storing phase compensated performance data and converting them into steady state performance characteristic curves of any non-linear shape.

Claims

1. A method of conducting a continuous performance analysis for a system, comprising the steps of:

collecting transient performance data for a first parameter of the system and a second parameter of the system using a first sensor and a second sensor, respectively;

supplying the transient performance data to a processor; and

applying transfer functions to the transient performance data for at least one of the first and second parameters, in the processor, to thereby generate phase compensated performance data representative of a steady state relationship between the first and second parameters; and

for each phase compensated performance datum, calculating, in the processor, an estimate of the first parameter at a predetermined value of the second parameter using the phase compensated performance datum and a previously stored performance characteristic curve representative of the steady state relationship between the first and second parameters.

2. The method of claim 1, wherein:

the predetermined value of the second parameter is a predetermined maximum rated value of the second parameter; and

the calculated estimate of the first parameter is a calculated estimate of a maximum value of the first value at the predetermined maximum rated value of the second parameter.

3. The method of claim 2, further comprising:

subtracting, in the processor, the maximum value of the first value from a predetermined first parameter limit value to obtain a first parameter margin.

4. The method of claim 1, further comprising:

filtering, in the processor, each of the calculated estimates of the first parameter to generate filtered first parameter estimate values.

5. The method of claim 4, further comprising:

detecting, in the processor, whether the filtered first parameter estimate values have changed by a predetermined magnitude; and

generating, in the processor, a reset signal if the filtered first parameter estimate values have changed by the predetermined magnitude.

6. The method of claim 1, further comprising:

providing, in a memory a predetermined number of data storage bins, each data storage bin representative of a predefined value range of the second parameter; and

storing, in the memory, the phase compensated performance data in an appropriate one of the data storage bins.

7. The method of claim 6, wherein:

the second parameter ranges in value from 1% to 130%; and

the predefined value range of each data storage bin is 1%, thereby resulting in 130 storage bins being provided.

8. The method of claim 6, further comprising:

generating, in the processor, a performance characteristic curve from the phase compensated performance data stored in each of the data storage bins.

9. The method of claim 8, further comprising:

recursively calculating, in the processor, a mean and a standard deviation of the phase compensated performance data stored in each of the data storage bins; and

generating, in the processor, the performance characteristic curve using the recursively calculated mean and standard deviation values.

10. The method of claim 1, further comprising:

filtering, in the processor, each of the calculated estimates of the first parameter to generate filtered first parameter estimate values;

detecting, in the processor, whether the filtered first parameter estimate values have changed by a predetermined magnitude; and

if the filtered first parameter estimate values have changed by the predetermined magnitude, generating, in the processor, the performance characteristic curve from the phase compensated performance data stored in each of the data storage bins after determining that the filtered first parameter estimate values have changed by the predetermined magnitude.

11. A method of conducting a continuous performance analysis for a gas turbine engine, comprising the steps of:

collecting transient performance data for a first engine parameter and a second engine parameter using a first sensor and a second sensor, respectively;

supplying the transient performance data to a processor; and

applying transfer functions to the transient performance data for at least one of the first and second engine parameters, in the processor, to thereby generate phase compensated engine performance data representative of a steady state relationship between the first and second engine parameters; and

for each phase compensated engine performance datum, calculating, in the processor, an estimate of the first engine parameter at a predetermined value of the second engine parameter using the phase compensated engine performance datum and a previously stored performance characteristic curve representative of the steady state relationship between the first and second engine parameters.

12. The method of claim 11, wherein:

the first engine parameter is power turbine inlet temperature;

the second engine parameter is engine torque;

the predetermined value of the second engine parameter is maximum rated power torque; and

the calculated estimate of the first engine parameter is a calculated estimate of power turbine inlet temperature at the maximum rated power torque.

13. The method of claim 12, further comprising:

providing, in a memory a predetermined number of data storage bins, each data storage bin representative of a predefined value range of engine torque; and

storing, in the memory, the phase compensated performance data in an appropriate one of the data storage bins.

14. The method of claim 13, wherein:

the engine torque ranges in value from 1% to 130%; and

the predefined value range of each data storage bin is 1%, thereby resulting in 130 storage bins being provided.

15. The method of claim 13, further comprising:

generating, in the processor, a performance characteristic curve from the phase compensated performance data stored in each of the data storage bins.

16. The method of claim 15, further comprising:

recursively calculating, in the processor, a mean and a standard deviation of the phase compensated performance data stored in each of the data storage bins; and

generating, in the processor, the performance characteristic curve using the recursively calculated mean and standard deviation values.

17. The method of claim 12, further comprising:

filtering, in the processor, each of the calculated estimates of the power turbine inlet temperature at the maximum rated power to generate filtered maximum power inlet temperature data;

detecting, in the processor, whether the filtered maximum power inlet temperature data change a predetermined magnitude; and

generating, in the processor, a reset signal if the filtered maximum power inlet temperature data change the predetermined magnitude.

18. The method of claim 12, further comprising:

calculating, in the processor, power turbine inlet temperature margin from a predetermined power turbine inlet temperature limit value and the calculated estimate of power turbine inlet temperature at the maximum rated power torque; and

calculating, in the processor, power available from the engine.

19. A gas turbine engine continuous performance analysis system, comprising:

a first sensor operable to sense a first engine parameter and supply first transient performance data representative of the first engine parameter;

a second sensor operable to sense a second engine parameter and supply second transient performance data representative of the second engine parameter;

a processor coupled to receive the first and second transient performance data from the first and second sensors, respectively, the processor operable, upon receipt thereof, to;

apply transfer functions to at least one of the first and second transient performance data to thereby generate phase compensated engine performance data representative of a steady state relationship between the first and second engine parameters; and

for each phase compensated engine performance datum, calculating an estimate of the first engine parameter at a predetermined value of the second engine parameter using the phase compensated engine performance datum and a previously stored performance characteristic curve representative of the steady state relationship between the first and second engine parameters.

20. The system of claim 19, wherein:

the first engine parameter is power turbine inlet temperature;

the second engine parameter is engine torque;

the predetermined value of the second engine parameter is maximum rated power torque; and

the calculated estimate of the first engine parameter is a calculated estimate of power turbine inlet temperature at the maximum rated power torque.