System and method for load power management in a turboshaft gas turbine engine

• US 9,494,085 B2
• Filed: 01/19/2015
• Issued: 11/15/2016
• Est. Priority Date: 01/19/2015
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Cai, Chaohong
• Primary Examiner(s): Black, Thomas G
• Assistant Examiner(s): PAIGE, TYLER D
• Application Number:
  US14/599,937
• Publication Number:
  US 20160208717A1
• Time in Patent Office: 666 Days
• Field of Search: 701/100, 607/73, 244/60
• US Class Current: 1/1
• CPC Class Codes: F02C 3/10 with another turbine driving an output shaft but not driving the compressor
• CPC Class Codes: F02C 9/54 by throttling the working fluid, by adjusting vanes
• CPC Class Codes: F05D 2220/329 in helicopters
• CPC Class Codes: F05D 2270/021 to prevent overspeed
• CPC Class Codes: F05D 2270/052 Torque
• CPC Class Codes: F05D 2270/101 Compressor surge or stall
• CPC Class Codes: F05D 2270/304 Spool rotational speed
• CPC Class Codes: F05D 2270/335 Output power or torque
• CPC Class Codes: F05D 2270/44 active, predictive, or anticipative
• CPC Class Codes: F05D 2270/705 proportional-integral

Abstract

A control system for a gas turbine engine including a power turbine is disclosed. The control system may also include an outer loop control module to determine a torque request. The outer loop control module may include a feedback control component operative to provide regulation of the power turbine, a feed-forward component operative to anticipate a load on the power turbine, and a hybrid control component operative to prevent output of a torque request that cannot currently be delivered by the power turbine. The control system may also include an inner loop control module to receive the torque request from the outer loop control module, to determine fuel flow and inlet guide vane schedules based at least in part on the received torque request, and to send signals to control a gas generator of the gas turbine engine according to the determined fuel flow and inlet guide vane schedules.

Claims

1. A control system for a gas turbine engine including a power turbine, the control system comprising:

an outer loop control module configured to output a current power turbine torque request (Qpt_req), the outer loop control module comprising;

a feedback control component configured to provide regulation of the power turbine;

a feed-forward component configured to anticipate a load on the power turbine; and

a hybrid control component configured to cause the feedback control component to switch to a decay dynamic if a previously determined power turbine torque request (Qpt_req) deviates more than a predetermined amount from a currently delivered torque of the power turbine; and

an inner loop control module configured to receive the current power turbine torque request (Qpt_req) from the outer loop control module, to determine fuel flow and inlet guide vane schedules based at least in part on the received current power turbine torque request (Qpt_req), and to send signals to a gas generator of the gas turbine engine in order to control the gas generator according to the determined fuel flow and inlet guide vane schedules.

2. The control system of claim 1, wherein the outer loop control module determines the current power turbine torque request (Qpt_req) based at least in part on a real-time collective lever angle command.

3. The control system of claim 1, wherein the load is produced by a rotor coupled to the power turbine.

4. The control system of claim 3, wherein the feed-forward component includes predetermined rotor load maps for an airframe containing the power turbine and the rotor.

5. The control system of claim 1, wherein the feedback control component comprises a Proportional Integral control component.

6. The control system of claim 5, wherein the Proportional Integral control component includes an integrator operative to produce an integral control signal (U_int).

7. The control system of claim 6, wherein the hybrid control component is configured to cause the integrator to switch to the decay dynamic if the previously determined power turbine torque request (Qpt_req) deviates more than a predetermined amount from the currently delivered torque of the power turbine.

8. The control system of claim 7, wherein the hybrid control component receives the integral control signal (U_int), a power turbine torque error signal (Qpt_error) comprising the previously determined power turbine torque request (Qpt_req) minus one of a measured or estimated value of the currently delivered torque of the power turbine, and a power turbine speed error signal (NP_error) comprising a desired power turbine speed minus a measured speed of the power turbine, wherein the hybrid control component is configured to cause the integrator to converge to zero if either of the following conditions are present during a period of time:

(A) U_int is greater than zero

and either;

1) the previously determined Qpt_req is greater than a predetermined maximum limit;

or

2) NP_error is greater than a first predetermined positive threshold value and

Qpt_error is greater than a second predetermined positive threshold value.

(B) U_int is less than zero

and either;

1) the previously determined Qpt_req is less than a predetermined minimum limit;

or

2) NP_error is less than a first predetermined negative threshold value and

Qpt_error is less than a second predetermined negative threshold value.

9. The control system of claim 1, further comprising a load estimation module configured to communicate with the outer loop control module, the inner loop control module, and the gas turbine engine, the load estimation module configured to generate signals indicative of a real-time estimated power turbine speed and a real-time estimated power turbine torque.

10. The control system of claim 1, wherein the inner loop control module determines the fuel flow and inlet guide vane schedules based at least in part on a real-time estimated power turbine speed.

11. A turboshaft engine, comprising:

a gas generator section;

a power turbine section downstream of the gas generator section; and

a control system in communication with the gas generator section and the power turbine section, the control system comprising;

an outer loop control module configured to output a current power turbine torque request (Qpt_req), the outer loop control module comprising;

a feedback control component configured to provide regulation of the power turbine;

a feed-forward component configured to anticipate a load on the power turbine; and

a hybrid control component configured to cause the feedback control component to switch to a decay dynamic if a previously determined power turbine torque request (Qpt_req) deviates more than a predetermined amount from a currently delivered torque of the power turbine; and

an inner loop control module configured to receive the current power turbine torque request (Qpt_req) from the outer loop control module, to determine fuel flow and inlet guide vane schedules based at least in part on the received current power turbine torque request (Qpt_req), and to send signals to a gas generator of the gas turbine engine in order to control the gas generator according to the determined fuel flow and inlet guide vane schedules.

12. The control system of claim 11, wherein the outer loop control module determines the current power turbine torque request (Qpt_req) based at least in part on a real-time collective lever angle command.

13. The control system of claim 11, wherein the load is produced by a rotor coupled to the power turbine.

14. The control system of claim 13, wherein the feed-forward component includes predetermined rotor load maps for an airframe containing the power turbine and the rotor.

15. The control system of claim 11, wherein the feedback control component comprises a Proportional Integral control component.

16. The control system of claim 15, wherein the Proportional Integral control component includes an integrator operative to produce an integral control signal (U_int).

17. The control system of claim 16, wherein the hybrid control component is configured to cause the integrator to switch to the decay dynamic if the previously determined power turbine torque request (Qpt_req) deviates more than a predetermined amount from the currently delivered torque of the power turbine.

18. The control system of claim 17, wherein the hybrid control component receives the integral control signal (U_int), a power turbine torque error signal (Qpt_error) comprising the previously determined power turbine torque request (Qpt_req) minus one of a measured or estimated value of the currently delivered torque of the power turbine, and a power turbine speed error signal (NP_error) comprising a desired power turbine speed minus a measured speed of the power turbine, wherein the hybrid control component is configured to cause the integrator to converge to zero if either of the following conditions are present during a period of time:

(A) U_int is greater than zero

and either;

1) the previously determined Qpt_req is greater than a predetermined maximum limit;

or

2) NP_error is greater than a first predetermined positive threshold value and

Qpt_error is greater than a second predetermined positive threshold value.

(B) U_int is less than zero

and either;

1) the previously determined Qpt_req is less than a predetermined minimum limit;

or

2) NP_error is less than a first predetermined negative threshold value and

Qpt_error is less than a second predetermined negative threshold value.

19. The control system of claim 11, further comprising a load estimation module configured to communicate with the outer loop control module, the inner loop control module, and the gas turbine engine, the load estimation module configured to generate signals indicative of a real-time estimated power turbine speed and a real-time estimated power turbine torque.

20. The control system of claim 11, wherein the inner loop control module determines the fuel flow and inlet guide vane schedules based at least in part on a real-time estimated power turbine speed.