Amy Chicatelli

Sensor Selection and Optimization for Health Assessment of Aerospace Systems

Abstract Aerospace systems are developed similarly to other large-scale systems through a series of reviews, where designs are modified as system requirements are refined. For space-based systems few are built and placed into service—these research vehicles have limited historical experience to draw from and formidable reliability and safety requirements, due to the remote and severe environment of space. Aeronautical systems have similar reliability and safety requirements, and while these systems may have historical information to access, commercial and military systems require longevity under a range of operational conditions and applied loads. Historically, the design of aerospace systems, particularly the selection of sensors, is based on the requirements for control and performance rather than on health assessment needs. Furthermore, the safety and reliability requirements are met through sensor suite augmentation in an ad hoc, heuristic manner, rather than any systematic approach. A review of the current sensor selection practice within and outside of the aerospace community was conducted and a sensor selection architecture is proposed that will provide a justifiable, defendable sensor suite to address system health assessment requirements.

Model-Based Control of a Nonlinear Aircraft Engine Simulation using an Optimal Tuner Kalman Filter Approach

This paper covers the development of a model-based engine control (MBEC) methodology featuring a self tuning on-board model applied to an aircraft turbofan engine simulation. Here, the Commercial Modular Aero-Propulsion System Simulation 40,000 (CMAPSS40k) serves as the MBEC application engine. CMAPSS40k is capable of modeling realistic engine performance, allowing for a verification of the MBEC over a wide range of operating points. The on-board model is a piece-wise linear model derived from CMAPSS40k and updated using an optimal tuner Kalman Filter (OTKF) estimation routine, which enables the on-board model to self-tune to account for engine performance variations. The focus here is on developing a methodology for MBEC with direct control of estimated parameters of interest such as thrust and stall margins. Investigations using the MBEC to provide a stall margin limit for the controller protection logic are presented that could provide benefits over a simple acceleration schedule that is currently used in traditional engine control architectures.

Addressing the Real-World Challenges in the Development of Propulsion IVHM Technology Experiment (PITEX)

‡‡ The Propulsion IVHM Technology Experiment (PITEX) has been an on-going research effort conducted over several years. PITEX has developed and applied a model-based diagnostic system for the main propulsion system of the X -34 reusable launch vehicle, a space-launch technology demonstrator. The application was simulation-based using detailed models of the propulsion subsystem to generate nominal and failure scenarios during captive carry, which is the most safety-critical portion of the X-34 flight. Since no system-level testing of the X-34 Main Propulsion System (MPS) was performed, these simulated data were used to verify and validate the software system. Advanced diagnostic and signal processing algorithms were developed and tested in real -time on flight-like hardware. In an attempt to expose potential performance problems, these PITEX algorithms were subject to numerous real-world effects in the simulated data includ ing noise, sensor resolution, command/valve talkback information, and nominal build variations. The current research has demonstrated the potential benefits of model-based diagnostics, defined the performance metrics required to evaluate the diagnostic system, and s tudied the impact of real-world challenges encountered when monitoring propulsion subsystems.

Model-Based Control of an Aircraft Engine using an Optimal Tuner Approach

This paper covers the development of a model-based engine control (MBEC) methodology applied to an aircraft turbofan engine. Here, a linear model extracted from the Commercial Modular Aero-Propulsion System Simulation 40,000 (CMAPSS40k) at a cruise operating point serves as the engine and the on-board model. The on-board model is updated using an optimal tuner Kalman Filter (OTKF) estimation routine, which enables the on-board model to self-tune to account for engine performance variations. The focus here is on developing a methodology for MBEC with direct control of estimated parameters of interest such as thrust and stall margins. MBEC provides the ability for a tighter control bound of thrust over the entire life cycle of the engine that is not achievable using traditional control feedback, which uses engine pressure ratio or fan speed. CMAPSS40k is capable of modeling realistic engine performance, allowing for a verication of the MBEC tighter thrust control. In addition, investigations of using the MBEC to provide a surge limit for the controller limit logic are presented that could provide benets over a simple acceleration schedule that is currently used in engine control architectures.

Advanced Control Considerations for Turbofan Engine Design

This paper covers the application of a model-based engine control (MBEC) methodology featuring a self tuning on-board model for an aircraft turbofan engine simulation. The nonlinear engine model is capable of modeling realistic engine performance, allowing for a verification of the advanced control methodology over a wide range of operating points and life cycle conditions. The on-board model is a piece-wise linear model derived from the nonlinear engine model and updated using an optimal tuner Kalman Filter estimation routine, which enables the on-board model to self-tune to account for engine performance variations. MBEC is used here to show how advanced control architectures can improve efficiency during the design phase of a turbofan engine by reducing conservative operability margins. The operability margins that can be reduced, such as stall margin, can expand the engine design space and offer potential for efficiency improvements. Application of MBEC architecture to a nonlinear engine simulation is shown to reduce the thrust specific fuel consumption by approximately 1% over the baseline design, while maintaining safe operation of the engine across the flight envelope.

Flight Simulator Evaluation of Enhanced Propulsion Control Modes for Emergency Operation

This paper describes piloted evaluation of enhanced propulsion control modes for emergency operation of aircraft. Fast Response and Overthrust modes were implemented to assess their ability to help avoid or mitigate potentially catastrophic situations, both on the ground and in flight. Tests were conducted to determine the reduction in takeoff distance achievable using the Overthrust mode. Also, improvements in Dutch roll damping, enabled by using yaw rate feedback to the engines to replace the function of a stuck rudder, were investigated. Finally, pilot workload and ability to handle the impaired aircraft on approach and landing were studied. The results showed that improvement in all aspects is possible with these enhanced propulsion control modes, but the way in which they are initiated and incorporated is important for pilot comfort and perceived benefit.

Propulsion Controls Modeling for a Small Turbofan Engine

A nonlinear dynamic model and propulsion controller are developed for a small-scale turbofan engine. The small-scale turbofan engine is based on the Price Induction company’s DGEN 380, one of the few turbofan engines targeted for the personal light jet category. Comparisons of the nonlinear dynamic turbofan engine model to actual DGEN 380 engine test data and a Price Induction simulation are provided. During engine transients, the nonlinear model typically agrees within 10% error, even though the nonlinear model was developed from limited available engine data. A gain scheduled proportional integral low speed shaft controller with limiter safety logic is created to replicate the baseline DGEN 380 controller. The new controller provides desired gain and phase margins and is verified to meet Federal Aviation Administration transient propulsion system requirements. In understanding benefits, there is a need to move beyond simulation for the demonstration of advanced control architectures and technologies by using real-time systems and hardware. The small-scale DGEN 380 provides a cost effective means to accomplish advanced controls testing on a relevant turbofan engine platform.