High temperature electronic monitoring system

• US 8,668,381 B2
• Filed: 12/23/2010
• Issued: 03/11/2014
• Est. Priority Date: 12/23/2010
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Weickert, John David, Bair, Eric John, Griffin, Gregory Keelen
• Primary Examiner(s): Caputo, Lisa
• Assistant Examiner(s): AHMED, NASIR UDDIN
• Application Number:
  US12/977,188
• Publication Number:
  US 20120163408A1
• Time in Patent Office: 1,174 Days
• Field of Search: 374/57, 374/4, 374/161, 374/137, 374/110, 374/12, 374/141, 374/144, 369/19, 369/59.1, 361/70, 361/74, 361/236, 364/557, 364/468.01, 364/528.25, 710/100, 731/120.1
• US Class Current: 374/57
• CPC Class Codes: F01D 21/003 Arrangements for testing or measuring for measuring vibrations G01H
• CPC Class Codes: F01D 21/12 responsive to temperature
• CPC Class Codes: F01D 25/285 Temporary support structures, e.g. for testing, assembling, installing, repairing; Assembly methods using such structures
• CPC Class Codes: F05D 2260/83 Testing, e.g. methods, components or tools therefor
• CPC Class Codes: F05D 2270/3032 excessive temperatures, e.g. caused by overheating
• CPC Class Codes: F05D 2270/802 Calibration thereof
• CPC Class Codes: G05B 23/0224 Process history based detection method, e.g. whereby history implies the availability of large amounts of data

Abstract

A system for monitoring performance parameters of an apparatus operating at an elevated temperature, such as a gas turbine engine. The system includes sensors for sensing the performance parameters and generating analog sensor outputs, at least one hub unit mounted sufficiently close to the apparatus so as to be subjected to a first temperature in excess of 125° C., a collector unit subjected to a second temperature of less than the first temperature, and a distributor computer unit subjected to a third temperature of less than the second temperature. The hub unit has control and signal conditioning circuit boards that operate together to condition the analog sensor outputs of the sensors and produce corresponding digital data. The collector unit transmits the digital data from the hub unit to the distributor computer unit, which processes the digital data to assess the performance parameters of the apparatus.

Claims

1. A monitoring system for monitoring performance parameters of an apparatus operating at an elevated temperature, the monitoring system comprising:

sensors mounted on the apparatus for sensing the performance parameters thereof and generating analog sensor outputs;

at least one hub unit mounted sufficiently close to the apparatus so as to be subjected to a first temperature in excess of 125°

C., the hub unit comprising means for receiving the analog sensor outputs from the sensors, a control circuit board, and at least one signal conditioning circuit board, the control circuit board and the signal conditioning circuit board operating together to condition the analog sensor outputs and produce corresponding digital data, the control circuit board and the signal conditioning circuit board comprising electrical circuit components that define an analog signal processing path and have accuracy and precision characteristics that drift in response to component aging and to changes in the first temperature to which the hub unit is subjected;

a collector unit mounted sufficiently close to the apparatus so as to be subjected to a second temperature of less than the first temperature, the collector unit comprising a power supply and means for receiving the digital data from the hub unit, the power supply supplying electrical power to the collector unit, the control circuit board and the signal conditioning circuit board of the hub unit, and the sensors, the collector unit comprising an enclosure containing a system voltage reference device and means for maintaining the system voltage reference device at a regulated temperature, the system voltage reference device producing a reference voltage;

means for performing a continuous calibration scheme by periodically applying the reference voltage and a zero voltage to the signal conditioning circuit board to determine and remove errors in the analog signal processing path resulting from the drifts of the electrical circuit components of the control circuit board and the signal conditioning circuit board; and

a distributor computer unit located sufficiently remote from the apparatus so as to be subjected to a third temperature of less than the second temperature, the distributor computer unit comprising means for receiving the digital data from the collector unit and means for processing the digital data to assess the performance parameters of the apparatus.

2. The monitoring system according to claim 1, wherein the hub unit is directly mounted on the apparatus.

3. The monitoring system according to claim 1, wherein the collector unit is directly mounted on the apparatus or a test stand supporting the apparatus.

4. The monitoring system according to claim 1, wherein the distributor computer unit is housed within an enclosure having a controlled environment.

5. The monitoring system according to claim 1, wherein the first temperature is in a range of in excess of 125°

C. up to at least 200°

C.

6. The monitoring system according to claim 1, wherein the second temperature is greater than 55°

C. and less than 125°

C., and the third temperature is less than 55°

C.

7. The monitoring system according to claim 1, wherein the means for performing the continuous calibration scheme periodically applies the reference voltage and the zero voltage to the signal conditioning circuit board at a frequency of more than once per second.

8. The monitoring system according to claim 1, wherein at least some of the electrical circuit components of the control circuit board and the signal conditioning circuit board are implemented on silicon-on-insulator substrates.

9. The monitoring system according to claim 1, wherein the electrical circuit components have a maximum operating temperature of greater than 125°

C.

10. The monitoring system according to claim 1, wherein the monitoring system lacks means for actively cooling the hub unit.

11. The monitoring system according to claim 1, wherein the reference voltage is a full scale voltage of the signal conditioning circuit board.

12. The monitoring system according to claim 1, wherein the removal of errors in the analog signal processing path with the means for performing the continuous calibration scheme results in the analog signal processing path having an accuracy of at least +/−

20 ppm.

13. The monitoring system according to claim 1, wherein the means for performing the continuous calibration scheme determines the errors in the analog signal processing path by comparing outputs generated by applying the reference voltage and the zero voltage to values of the reference voltage and the zero voltage, and then correcting subsequent digital data based on the comparison, and the means for performing the continuous calibration scheme completes the continuous calibration scheme each time analog sensor outputs are acquired.

14. The monitoring system according to claim 1, further comprising:

means on the signal conditioning circuit board for multiplexing a plurality of the analog sensor outputs generated by the sensors to produce an individual multiplexed analog output; and

at least one amplifier with adjustable gain for scaling the analog sensor outputs of the individual multiplexed analog output to produce an individual conditioned multiplexed analog output from which the corresponding digital data are produced, the amplifier and the adjustable gain thereof being controlled by the control circuit board.

15. The monitoring system according to claim 14, wherein the individual multiplexed analog output produced by the multiplexing means is one of a plurality of individual multiplexed analog outputs produced by the multiplexing means and scaled by the amplifier to produce a plurality of individual conditioned multiplexed analog outputs, and each of the individual multiplexed analog outputs is produced from a corresponding set of the analog sensor outputs generated by the sensors, wherein the signal conditioning circuit board further comprises means for interleaving the individual conditioned multiplexed analog outputs to reduce settling time between the sets of the analog sensor outputs and improve throughput to the control circuit board.

16. The monitoring system according to claim 15, wherein the interleaving means comprises a dynamic filter that switches passive RC components into and out of a circuit path containing the multiplexing means, the amplifier, and the interleaving means to increase throughput by reducing the settling time.

17. A monitoring system for monitoring engine performance parameters of a gas turbine engine while operating, the monitoring system comprising:

sensors mounted on the engine for sensing the engine performance parameters and generating analog sensor outputs;

at least one hub unit mounted sufficiently close to the engine so as to be subjected to a first temperature in excess of 125°

C., the hub unit comprising means for receiving the analog sensor outputs from the sensors, a control circuit board, and at least one signal conditioning circuit board, the control circuit board and the signal conditioning circuit board operating together to condition the analog sensor outputs and produce corresponding digital data, the control circuit board and the signal conditioning circuit board comprising electrical circuit components that define an analog signal processing path and have accuracy and precision characteristics that drift in response to component aging and to changes in the first temperature to which the hub unit is subjected;

a collector unit mounted sufficiently close to the engine so as to be subjected to a second temperature in excess of 55°

C. but less than 125°

C., the collector unit comprising means for receiving, logging and synchronizing the digital data from the hub unit, a power supply, an enclosure containing a system voltage reference device and means for maintaining the system voltage reference device at a regulated temperature, the power supply supplying electrical power to the collector unit, the control circuit board and the signal conditioning circuit board of the hub unit, and the sensors, the system voltage reference device producing a reference voltage;

means for performing a continuous calibration scheme by periodically applying the reference voltage and a zero voltage to the signal conditioning circuit board to determine and remove errors in the analog signal processing path resulting from the drifts of the electrical circuit components of the control circuit board and the signal conditioning circuit board;

means on the signal conditioning circuit board for multiplexing a plurality of the analog sensor outputs generated by the sensors to produce an individual multiplexed analog output;

at least one amplifier with adjustable gain for scaling the analog sensor outputs of the individual multiplexed analog output to produce an individual conditioned multiplexed analog output from which the corresponding digital data are produced, the amplifier and the adjustable gain thereof being controlled by the control circuit board; and

a distributor computer unit located sufficiently remote from the engine so as to be subjected to a third temperature of less than 55°

C., the distributor computer unit comprising means for receiving the digital data from the collector unit and means for processing the digital data to assess the engine performance parameters of the engine.

18. The monitoring system according to claim 17, wherein the hub unit is mounted beneath a cowling of the engine.

19. The monitoring system according to claim 17, wherein the collector unit is mounted on a test stand supporting the engine or a fan case of the engine.