Prognostic health management approaches for propulsion control system

• US 9,790,864 B2
• Filed: 03/11/2014
• Issued: 10/17/2017
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Rolls-Royce North American Technologies, Inc. (Rolls-Royce Holdings Plc)
• Original Assignee: Rolls-Royce North American Technologies, Inc. (Rolls-Royce Holdings Plc)
• Inventors: Skertic, Richard J., Myer, Joseph D.
• Primary Examiner(s): Do, Truc M
• Assistant Examiner(s): Whittington, Jess
• Application Number:
  US14/204,547
• Publication Number:
  US 20140277991A1
• Time in Patent Office: 1,316 Days
• CPC Class Codes: F02C 9/00 Controlling gas-turbine plants; Controlling fuel supply in air- breathing jet-propulsion plants controlling air intakes F02C7/057; controlling turbines F01D; controlling compressors F04D27/00; controlling in general G05
• CPC Class Codes: G05B 23/0289 Reconfiguration to prevent failure, e.g. usually as a reaction to incipient failure detection

Abstract

A real-time gas turbine management system includes a controller system coupled to a gas turbine engine. The controller system is configured to control demand on a first and second component of a gas turbine engine. The controller system is configured to identify a set point reference of the first component, identify a set point reference of the second component, and identify a data set indicative of a level of deterioration of the gas turbine engine. The controller system is also configured to change the set point reference of the first component to extend a lifespan of the gas turbine engine and/or change the set point reference of the second component to extend the lifespan of the gas turbine engine.

Claims

1. A real-time system, comprising:

a controller system having a system controller with a processor, the controller system being coupled to an engine and configured to control demand on a first and second component of the engine, the controller system is configured to;

operate the engine in a control mode associated with one of the first component and the second component;

identify, by way of the system controller, a set point reference of the first component;

identify, by way of the system controller, a set point reference of the second component;

identify, by way of the system controller, a data set indicative of a level of deterioration of the engine by at least referencing at least one reference schedule that associates a state of at least one of the first component and the second component with a given thrust;

based on the level of deterioration determine and implement a trim scheme, which includes increasing the set point reference of the first component if the control mode is a rotor speed control mode, and decreasing the set point reference of the second component if the control mode is one of an engine pressure ratio control mode and a turbine fan power ratio control mode;

wherein the set point reference of the first component is a fan speed set point reference and the set point reference of the second component is one of an engine pressure ratio set point reference and a turbo fan power ratio set point reference.

2. The real-time system as claimed in claim 1, further comprising a prognostic data unit having a processor and a memory and being configured to determine the level of deterioration of the engine.

3. The real-time system as claimed in claim 1, wherein the control system is further configured to:

receive a first set of sensed data indicative of a current operating characteristic of the first component; and

receive a second set of data indicative of a current operating characteristic of the second component.

4. The real-time system as claimed in claim 1, wherein the increase of the set point reference of the first component is based on the first set of sensed data and the data set indicative of the level of deterioration of the engine.

5. The real-time system as claimed in claim 1, wherein the decrease of the set point reference of the second component is based on a decrease in thrust from the engine.

6. The real-time system as claimed in claim 1, wherein the controller system is further configured to receive an engine control request, and wherein the change of the set point reference of the first component enables the engine to meet the engine control request.

7. The real-time system as claimed in claim 6, wherein the engine control request is a request for additional thrust.

8. The real-time system as claimed in claim 1, wherein the engine is a gas turbine.

9. The real-time system as claimed in claim 1, wherein the controller system is further configured to:

receive, by way of the system controller, an engine control request;

send, by way of the system controller, a plurality of control demands to the engine, wherein each of the plurality of control demands each respectively controls the first component and the second component;

receive, by way of the system controller, a real-time operating characteristic of each of the first component and the second component;

identify an increased level of degradation of the system; and

based on the identification of the increased level of degradation, modify at least one control demand of the plurality of control demands so that the engine control request is met.

10. The real-time system as claimed in claim 9, wherein the controller system is further configured to change the set point reference of the at least one control demand, wherein a modification of the at least one control demand is based on the trim scheme.

11. The real-time system as claimed in claim 10, wherein modification of the at least one control demand modifies a fuel flow to the engine.

12. The real-time system as claimed in claim 10, wherein the controller system is further configured to identify a difference between the at least one control demand and a sensed output of the first component, wherein the first component corresponds with the at least one control demand, and wherein the modification of the at least one control demand is based on the difference.

13. The real-time system as claimed in claim 1, further comprising an aircraft.

14. The real-time system as claimed in claim 3, wherein the controller system does not increase the set point reference of the first component or decrease the set point reference of the second component if at least one of the first sensed data and the second sensed data correspond to values in the at least one reference schedule.

15. An aircraft, comprising:

an engine; and

a controller system having a system controller with a processor, the controller system being coupled to an engine and configured to control demand on a first and second component of the engine, the controller system is configured to;

operate the engine in a control mode associated with one of the first component and the second component;

identify, by way of the system controller, a set point reference of the first component;

identify, by way of the system controller, a set point reference of the second component;

identify, by way of the system controller, a data set indicative of a level of deterioration of the engine by at least referencing at least one reference schedule that associates a state of at least one of the first component and the second component with a given thrust; and

based on the level of deterioration, determine and implement a trim scheme, which includes increasing the set point reference of the first component if the control mode is a rotor speed control mode, and decreasing the set point reference of the control mode is one of an engine pressure ratio control mode and a turbine fan power ratio control mode; and

notify a user to change the set point reference of the second component wherein the set point reference of the first component is a fan speed set point reference and the set point reference of the second component is one of an engine pressure ratio set point reference and a turbo fan power ratio set point reference.