Control considerations for optimum power proportionment in turbine-propeller engines
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NOZZLES, EXHAUST - VARIABLE↗
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Control system design for the MOD-5A 7.3 mW wind turbine generator
This paper provides descriptions of the requirements analysis, hardware development and software development phases of the Control System design for the MOD-5A 7.3 mW Wind Turbine Generator. The system, designed by General Electric Company, Advanced Energy Programs Department, under contract DEN 3-153 with NASA Lewis Research Center and DOE, provides real time regulation of rotor speed by control of both generator torque and rotor torque. A variable speed generator system is used to provide both airgap torque control and reactive power control. The wind rotor is designed with segmented ailerons which are positioned to control blade torque. The central component of the control system, selected early in the design process, is a programmable controller used for sequencing, alarm monitoring, communication, and real time control. Development of requirements for use of aileron controlled blades and a variable speed generator required an analytical simulation that combined drivetrain, tower and blade elastic modes with wind disturbances and control behavior. An orderly two phase plan was used for controller software development. A microcomputer based turbine simulator was used to facilitate hardware and software integration and test.
Barton, Robert S.↗
Modernizing engine displays
The introduction of electronic fuel control to modern turbine engines has a number of advantages, which are related to an increase in engine performance and to a reduction or elimination of the problems associated with high angle of attack engine operation from the surface to 50,000 feet. If the appropriate engine display devices are available to the pilot, the fuel control system can provide a great amount of information. Some of the wealth of information available from modern fuel controls are discussed in this paper. The considered electronic engine control systems in their most recent forms are known as the Full Authority Digital Engine Control (FADEC) and the Digital Electronic Engine Control (DEEC). Attention is given to some details regarding the control systems, typical engine problems, the solution of problems with the aid of displays, engine displays in normal operation, an example display format, a multipage format, flight strategies, and hardware considerations.
Schneider, E. T.↗
Sixth NASA Glenn Research Center Propulsion Control and Diagnostics (PCD) Workshop
The Intelligent Control and Autonomy Branch at NASA Glenn Research Center hosted the Sixth Propulsion Control and Diagnostics Workshop on August 22-24, 2017. The objectives of this workshop were to disseminate information about research being performed in support of NASA Aeronautics programs; get feedback from peers on the research; and identify opportunities for collaboration. There were presentations and posters by NASA researchers, Department of Defense representatives, and engine manufacturers on aspects of turbine engine modeling, control, and diagnostics.
Collaboration↗
Photoacoustic microscopy of ceramic turbine blades
Scanning photoacoustic microscopy (SPAM) is evaluated as a nondestructive technique for the detection of both surface and subsurface flaws in polycrystalline ceramics, such as those currently under consideration for the high temperature components of small vehicular and industrial gas turbine engines; the fracture strength of these brittle materials is controlled by small, 25-200 micron flaws. Attention is given to the correlation of SPAM-detected flaws with actual, fracture-controlling flaws in ceramic turbine blades.
Khandelwal, P. K.↗
Propulsion Control Technology Development in the United States A Historical Perspective
This paper presents a historical perspective of the advancement of control technologies for aircraft gas turbine engines. The paper primarily covers technology advances in the United States in the last 60 years (1940 to approximately 2002). The paper emphasizes the pioneering technologies that have been tested or implemented during this period, assimilating knowledge and experience from industry experts, including personal interviews with both current and retired experts. Since the first United States-built aircraft gas turbine engine was flown in 1942, engine control technology has evolved from a simple hydro-mechanical fuel metering valve to a full-authority digital electronic control system (FADEC) that is common to all modern aircraft propulsion systems. At the same time, control systems have provided engine diagnostic functions. Engine diagnostic capabilities have also evolved from pilot observation of engine gauges to the automated on-board diagnostic system that uses mathematical models to assess engine health and assist in post-flight troubleshooting and maintenance. Using system complexity and capability as a measure, we can break the historical development of control systems down to four phases: (1) the start-up phase (1942 to 1949), (2) the growth phase (1950 to 1969), (3) the electronic phase (1970 to 1989), and (4) the integration phase (1990 to 2002). In each phase, the state-of-the-art control technology is described and the engines that have become historical landmarks, from the control and diagnostic standpoint, are identified. Finally, a historical perspective of engine controls in the last 60 years is presented in terms of control system complexity, number of sensors, number of lines of software (or embedded code), and other factors.
Jaw, Link C.a↗
Adaptive Development
The goal of this research is to develop and demonstrate innovative adaptive seal technologies that can lead to dramatic improvements in engine performance, life, range, and emissions, and enhance operability for next generation gas turbine engines. This work is concentrated on the development of self-adaptive clearance control systems for gas turbine engines. Researchers have targeted the high-pressure turbine (HPT) blade tip seal location for following reasons: Current active clearance control (ACC) systems (e.g., thermal case-cooling schemes) cannot respond to blade tip clearance changes due to mechanical, thermal, and aerodynamic loads. As such they are prone to wear due to the required tight running clearances during operation. Blade tip seal wear (increased clearances) reduces engine efficiency, performance, and service life. Adaptive sealing technology research has inherent impact on all envisioned 21st century propulsion systems (e.g. distributed vectored, hybrid and electric drive propulsion concepts).
Source record↗
Concept Designed and Developed for Distortion- Tolerant, High-Stability Engine Control
Engine Control Future aircraft turbine engines, both commercial and military, must be able to successfully accommodate expected increased levels of steady-state and dynamic engine-face distortion. Advanced tactical aircraft are likely to use thrust vectoring to enhance their maneuverability. As a result, the engines will see more extreme aircraft angles-of-attack and sideslip levels than are currently encountered with present-day aircraft. Also, the mixed-compression inlets needed for the High Speed Civil Transport will likely encounter disturbances similar to those seen by tactical aircraft, in addition to planar pulse, inlet buzz, and high distortion levels at low flight speed and off-design operation. The current approach of incorporating a sufficient component design stall margin to tolerate these increased levels of distortion would significantly reduce performance. The objective of the High Stability Engine Control (HISTEC) program is to design, develop, and flight demonstrate an advanced, high-stability, integrated engine-control system that uses measurement-based, real-time estimates of distortion to enhance engine stability. The resulting distortion-tolerant control reduces the required design stall margin, with a corresponding increase in performance and decrease in fuel burn. The HISTEC concept has been designed and developed, and the software implementing the concept has successfully accommodated time-varying distortion. The NASA Lewis Research Center is currently overseeing the development and validation of the hardware and software necessary to flight test the HISTEC concept. HISTEC is a contracted effort with Pratt & Whitney of West Palm Beach, Florida. The HISTEC approach includes two major systems: A Distortion Estimation System (DES) and Stability Management Control (SMC). DES is an aircraft-mounted, high-speed processor that estimates the amount and type of distortion present and its effect on the engine. It uses high-response pressure measurements at the engine face to calculate indicators of the type and extent of distortion in real time. From these indicators, DES determines the effects of distortion on the propulsion systems and the corresponding engine match point necessary to accommodate it. DES output consists of fan and compressor pressure ratio trim commands that are passed to the SMC. In addition, DES uses maneuver information, consisting of angle-of-attack and sideslip from the flight control, to anticipate high inlet distortion conditions. The SMC, which is contained in the engine-mounted, Improved Digital Electronic Engine Control (IDEEC), includes advanced control laws to directly control the fan and compressor transient operating line (pressure ratio). These advanced control laws, with a multivariable design, have the potential for higher bandwidth and the resulting more precise control of engine match. The ability to measure and assess the distortion effects in real time coupled with a high-response controller improves engine stability at high levels of distortion. The software algorithms implementing DES have been designed, developed, and demonstrated, and integration testing of the DES and SMC software has been completed. The results show that the HISTEC system will be able to sense inlet distortion, determine the effect on engine stability, and accommodate distortion by maintaining an adequate margin for engine surge. The Pratt &Whitney Comprehensive Engine Diagnostic Unit was chosen as the DES processor. An instrumented inlet case for sensing distortion was designed and fabricated. HISTEC is scheduled for flight test on the ACTIVE F-15 aircraft at the NASA Dryden Flight Research Center in Edwards, California, in late 1996.
Source record↗
Combustion Dynamics and Control for Ultra Low Emissions in Aircraft Gas-Turbine Engines
Future aircraft engines must provide ultra-low emissions and high efficiency at low cost while maintaining the reliability and operability of present day engines. The demands for increased performance and decreased emissions have resulted in advanced combustor designs that are critically dependent on efficient fuel/air mixing and lean operation. However, all combustors, but most notably lean-burning low-emissions combustors, are susceptible to combustion instabilities. These instabilities are typically caused by the interaction of the fluctuating heat release of the combustion process with naturally occurring acoustic resonances. These interactions can produce large pressure oscillations within the combustor and can reduce component life and potentially lead to premature mechanical failures. Active Combustion Control which consists of feedback-based control of the fuel-air mixing process can provide an approach to achieving acceptable combustor dynamic behavior while minimizing emissions, and thus can provide flexibility during the combustor design process. The NASA Glenn Active Combustion Control Technology activity aims to demonstrate active control in a realistic environment relevant to aircraft engines by providing experiments tied to aircraft gas turbine combustors. The intent is to allow the technology maturity of active combustion control to advance to eventual demonstration in an engine environment. Work at NASA Glenn has shown that active combustion control, utilizing advanced algorithms working through high frequency fuel actuation, can effectively suppress instabilities in a combustor which emulates the instabilities found in an aircraft gas turbine engine. Current efforts are aimed at extending these active control technologies to advanced ultra-low-emissions combustors such as those employing multi-point lean direct injection.
DeLaat, John C.↗
Minimum fan turbine inlet temperature mode evaluation
Measured reductions in turbine temperature which resulted from the application of the F-15 performance seeking control (PSC) minimum fan turbine inlet temperature (FTIT) mode during the dual-engine test phase is presented as a function of net propulsive force and flight condition. Data were collected at altitudes of 30,000 and 45,000 feet at military and partial afterburning power settings. The FTIT reductions for the supersonic tests are less than at subsonic Mach numbers because of the increased modeling and control complexity. In addition, the propulsion system was designed to be optimized at the mid supersonic Mach number range. Subsonically at military power, FTIT reductions were above 70 R for either the left or right engines, and repeatable for the right engine. At partial afterburner and supersonic conditions, the level of FTIT reductions were at least 25 R and as much as 55 R. Considering that the turbine operates at or very near its temperature limit at these high power settings, these seemingly small temperature reductions may significantly lengthen the life of the turbine. In general, the minimum FTIT mode has performed well, demonstrating significant temperature reductions at military and partial afterburner power. Decreases of over 100 R at cruise flight conditions were identified. Temperature reductions of this magnitude could significantly extend turbine life and reduce replacement costs.
Orme, John S.↗
Effect of thermal cycling on ZrO2-Y2O3 thermal barrier coatings
The paper studies the comparative life of plasma-sprayed ZrO2-Y2O3 thermal barrier coatings on NiCrAlY bond coats on Rene 41 in short (4 min) and long (57 min) thermal cycles at 1040 C in a 0.3-Mach flame. Attention is given to determining the effect of short- and long-duration cycles on ZrO2-Y2O3 coatings, the cause of any cycle frequency effects, and methods to improve tolerance to thermal stress. Short cycles greatly reduced the life of the ceramic coating in terms of time at temperatures as compared to longer cycles, the failed coating indicating compressive failure. The experiments and stress calculations show that repeatedly subjecting a ceramic coating to high rates of initial heating has a more destructive influence on the coating than sustained operation at temperature. The effect of such thermal compressive stresses might be minimized through coating deposition and thickness control and by turbine cycle measurement to keep starting heating rates below critical values.
Mcdonald, G.↗
Alternatives for jet engine control
Research centered on basic topics in the modeling and feedback control of nonlinear dynamical systems is reported. Of special interest were the following topics: (1) the role of series descriptions, especially insofar as they relate to questions of scheduling, in the control of gas turbine engines; (2) the use of algebraic tensor theory as a technique for parameterizing such descriptions; (3) the relationship between tensor methodology and other parts of the nonlinear literature; (4) the improvement of interactive methods for parameter selection within a tensor viewpoint; and (5) study of feedback gain representation as a counterpart to these modeling and parameterization ideas.
Sain, M. K.↗
Wind turbine generator interaction with conventional diesel generators on Block Island, Rhode Island. Volume 2: Data analysis
Assessing the performance of a MOD-OA horizontal axis wind turbine connected to an isolated diesel utility, a comprehensive data measurement program was conducted on the Block Island Power Company installation on Block Island, Rhode Island. The detailed results of that program focusing on three principal areas of (1) fuel displacement (savings), (2) dynamic interaction between the diesel utility and the wind turbine, (3) effects of three models of wind turbine reactive power control are presented. The approximate two month duration of the data acquisition program conducted in the winter months (February into April 1982) revealed performance during periods of highest wind energy penetration and hence severity of operation. Even under such conditions fuel savings were significant resulting in a fuel reduction of 6.7% while the MOD-OA was generating 10.7% of the total electrical energy. Also, electrical disturbance and interactive effects were of an acceptable level.
Wilreker, V. F.↗
Preliminary flight test results of the F100 EMD engine in an F-15 airplane
An assessment is given of results from a 17-flight evaluation of the F100 Engine Model Derivative (EMD) powerplant in an F-15 fighter. The EMD variant of the F100 engine incorporates a larger fan, a higher temperature turbine, a digital control system, and a 16-segment afterburner. These modifications result in a 15 to 20 percent increase in thrust which is exhibited in the reduction of F-15 acceleration time to Mach 2.0 by 23 percent. The only uncorrected shortcoming of the engine upon completion of the 17-flight test course was the occurrence of compressor stalls at the throttle's idle setting. These stalls had not been predicted by either ground facility tests or compressor stability assessments.
Myers, L. P.↗
Research Reports: 1988 NASA/ASEE Summer Faculty Fellowship Program
The basic objectives are to further the professional knowledge of qualified engineering and science faculty members; to stimulate an exchange of ideas between participants and NASA: to enrich and refresh the research and teaching activities of the participants' institutions; and to contribute to the research objectives of the NASA centers. Topics addressed include: cryogenics; thunderstorm simulation; computer techniques; computer assisted instruction; system analysis weather forecasting; rocket engine design; crystal growth; control systems design; turbine pumps for the Space Shuttle Main engine; electron mobility; heat transfer predictions; rotor dynamics; mathematical models; computational fluid dynamics; and structural analysis.
Freeman, L. Michael↗
Advanced detection, isolation, and accommodation of sensor failures in turbofan engines: Real-time microcomputer implementation
The objective of the Advanced Detection, Isolation, and Accommodation Program is to improve the overall demonstrated reliability of digital electronic control systems for turbine engines. For this purpose, an algorithm was developed which detects, isolates, and accommodates sensor failures by using analytical redundancy. The performance of this algorithm was evaluated on a real time engine simulation and was demonstrated on a full scale F100 turbofan engine. The real time implementation of the algorithm is described. The implementation used state-of-the-art microprocessor hardware and software, including parallel processing and high order language programming.
Delaat, John C.↗
Automated Blast Cleaner
Automatic grit-blasting machine removes melted-layer residue from electrical-discharge-machined surfaces of turbine blades. Automatic control system of machine provides steady flow of grit and maintains blast nozzles at proper distance and in correct orientation perpendicular to surface being blasted, regardless of contour. Eliminates localized excessive blasting and consequent excessive removal of underlying material, blasting of adjacent surfaces, and missed areas.
Pickett, Isaiah R.↗
Potassium-Rankine Power Conversion Subsystem Modeling for Nuclear Electric Propulsion
A potassium-Rankine power conversion system model was developed under Contract No. NAS3-25808 for the NASA-LeRC. This model predicts potassium-Rankine performance for turbine inlet temperatures (TIT) from 1200 - 1600 K, TIT to condenser temperature ratios from 1.25-1.6, power levels from 100 to 10,000 kWe, and lifetimes from 2-10 years. The model is for a Rankine cycle with reheat for turbine stage moisture control. The model assumes heat is supplied from a lithium heat transport loop. The model does not include a heat source or a condenser/heat rejection system model. These must be supplied by the user.
Johnson, Gregory A.↗