Jonathan L. Kratz

Developing an Integration Infrastructure for Distributed Engine Control Technologies

Turbine engine control technology is poised to make the first revolutionary leap forward since the advent of full authority digital engine control in the mid-1980s. This change aims squarely at overcoming the physical constraints that have historically limited control system hardware on aero-engines to a federated architecture. Distributed control architecture allows complex analog interfaces existing between system elements and the control unit to be replaced by standardized digital interfaces. Embedded processing, enabled by high temperature electronics, provides for digitization of signals at the source and network communications resulting in a modular system at the hardware level. While this scheme simplifies the physical integration of the system, its complexity appears in other ways. In fact, integration now becomes a shared responsibility among suppliers and system integrators. While these are the most obvious changes, there are additional concerns about performance, reliability, and failure modes due to distributed architecture that warrant detailed study. This paper describes the development of a new facility intended to address the many challenges of the underlying technologies of distributed control. The facility is capable of performing both simulation and hardware studies ranging from component to system level complexity. Its modular and hierarchical structure allows the user to focus their interaction on specific areas of interest.

A Parametric Study of Actuator Requirements for Active Turbine Tip Clearance Control of a Modern High Bypass Turbofan Engine

The efficiency of aircraft gas turbine engines is sensitive to the distance between the tips of its turbine blades and its shroud, which serves as its containment structure. Maintaining tighter clearance between these components has been shown to increase turbine efficiency, increase fuel efficiency, and reduce the turbine inlet temperature, and this correlates to a longer time-on-wing for the engine. Therefore, there is a desire to maintain a tight clearance in the turbine, which requires fast response active clearance control. Fast response active tip clearance control will require an actuator to modify the physical or effective tip clearance in the turbine. This paper evaluates the requirements of a generic active turbine tip clearance actuator for a modern commercial aircraft engine using the Commercial Modular Aero-Propulsion System Simulation 40k (C-MAPSS40k) software that has previously been integrated with a dynamic tip clearance model. A parametric study was performed in an attempt to evaluate requirements for control actuators in terms of bandwidth, rate limits, saturation limits, and deadband. Constraints on the weight of the actuation system and some considerations as to the force which the actuator must be capable of exerting and maintaining are also investigated. From the results, the relevant range of the evaluated actuator parameters can be extracted. Some additional discussion is provided on the challenges posed by the tip clearance control problem and the implications for future small core aircraft engines. INTRODUCTION Turbine tip clearance refers to the distance between the turbine blades and their containment structure. The tip clearance changes over the course of a flight due to thermal expansion, centrifugal forces of the spinning components, and the mechanical loads applied to the structures by aerodynamic forces and internal stresses. Axisymmetric tip clearance variations are the most significant and include the contributions of thermal expansion and the elongation of moving components due to axisymmetric thermal and mechanical loads. Capturing these components of the tip clearance variation is the focus of the tip clearance model used in this study. A physical explanation of the variation of the tip clearance gap begins with any change in engine operating condition. Consider an increase in power. As the rotor and blade increase in speed, the centrifugal force exerted on these components increases causing them to expand. Additionally, as the temperature in the gas path increases the turbine components heat up and expand. Due to differences in size, geometry, materials, and heat transfer rates, the components of the turbine expand at different rates and reach different steady-state deformations. Note that throughout this paper deformation will be used to characterize an elongation or contraction of a turbine component. This is not to be confused with twisting or bending. Deformation of the blade and rotor occurs relatively quickly due to acceleration of the high pressure spool (HPS). The blade deformation is accelerated further by its relatively fast thermal expansion because of its relatively low mass and large surface area, and its direct exposure to the hot gas path. The rotor and the containment structure around the turbine are larger and experience weaker heat transfer leading to much slower thermal transients and therefore slower expansion. These differences in magnitude and rate of expansion, particularly between the internal engine components and containment structure, create ‘pinch points’ where the tip clearance is significantly reduced during fast accelerations of the engine that are accompanied by rapid changes in the gas path temperature. These pinch points lead to conservative and less efficient design decisions. Modern commercial gas turbine engines employ slow acting thermal management techniques for controlling the tip clearance in the high pressure turbine (HPT) and low pressure turbine (LPT) [1]. Due to the lack of tip clearance sensors https://ntrs.nasa.gov/search.jsp?R=20170008736 2018-05-22T18:03:08+00:00Z

Design and Benchmarking of a Network-In-the-Loop Simulation for Use in a Hardware-In-the-Loop System

Distributed engine control (DEC) systems alter aircraft engine design constraints because of fundamental differences in the input and output communication between DEC and centralized control architectures. The change in the way communication is implemented may create new optimum engine-aircraft configurations. This paper continues the exploration of digital network communication by demonstrating a Network-In-the-Loop simulation at the NASA Glenn Research Center. This simulation incorporates a real-time network protocol, the Engine Area Distributed Interconnect Network Lite (EADIN Lite), with the Commercial Modular Aero-Propulsion System Simulation 40k (C-MAPSS40k) software. The objective of this study is to assess digital control network impact to the control system. Performance is evaluated relative to a truth model for large transient maneuvers and a typical flight profile for commercial aircraft. Results show that a decrease in network bandwidth from 250 Kbps (sampling all sensors every time step) to 40 Kbps, resulted in very small differences in control system performance.

Approximation of Engine Casing Temperature Constraints for Casing Mounted Electronics

The performance of propulsion engine systems is sensitive to weight and volume considerations. This can severely constrain the configuration and complexity of the control system hardware. Distributed Engine Control technology is a response to these concerns by providing more flexibility in designing the control system, and by extension, more functionality leading to higher performing engine systems. Consequently, there can be a weight benefit to mounting modular electronic hardware on the engine core casing in a high temperature environment. This paper attempts to quantify the in-flight temperature constraints for engine casing mounted electronics. In addition, an attempt is made at studying heat soak back effects. The Commercial Modular Aero Propulsion System Simulation 40k (C-MAPSS40k) software is leveraged with real flight data as the inputs to the simulation. A two-dimensional (2-D) heat transfer model is integrated with the engine simulation to approximate the temperature along the length of the engine casing. This modification to the existing C-MAPSS40k software will provide tools and methodologies to develop a better understanding of the requirements for the embedded electronics hardware in future engine systems. Results of the simulations are presented and their implications on temperature constraints for engine casing mounted electronics is discussed.

Integrated Turbine Tip Clearance and Gas Turbine Engine Simulation

Gas turbine compressor and turbine blade tip clearance (i.e., the radial distance between the blade tip of an axial compressor or turbine and the containment structure) is a major contributing factor to gas path sealing, and can significantly affect engine efficiency and operational temperature. This paper details the creation of a generic but realistic high pressure turbine tip clearance model that may be used to facilitate active tip clearance control system research. This model uses a first principles approach to approximate thermal and mechanical deformations of the turbine system, taking into account the rotor, shroud, and blade tip components. Validation of the tip clearance model shows that the results are realistic and reflect values found in literature. In addition, this model has been integrated with a gas turbine engine simulation, creating a platform to explore engine performance as tip clearance is adjusted. Results from the integrated model explore the effects of tip clearance on engine operation and highlight advantages of tip clearance management.

Turbine Electrified Energy Management (TEEM) For Enabling More Efficient Engine Designs

NASA is investing in Electrified Aircraft Propulsion (EAP) research as part of an effort to assist industry in meeting the future needs of a global aviation market. The integration of electric machines into traditional turbine-based propulsion provides opportunities to change system architectures effecting radical improvements in propulsive efficiency. However, less consideration has been afforded to the utilization of these electrical machines to improve the thermal efficiency and performance of the gas turbine engine. Noting this deficit, a novel operability concept is proposed and is referred to as Turbine Electrified Energy Management (TEEM). The concept is a transient control technology that supplements the main fuel control for the suppression of the natural off-design dynamics associated with changes in engine operating state. Here the electric machines, used as engine actuators during the transient, add or extract torque from the engine shafts to maintain the speed-flow characteristics of steadystate design operation. This greatly reduces the need to maintain transient stall margin stack in the compressors, among other potential benefits. This paper demonstrates the feasibility of the concept in dynamic simulation using a Numerical Propulsion System Simulation (NPSS) engine model of a NASA hybrid electric propulsion concept known as the Parallel Hybrid Electric Turbofan (hFan).

Dynamic Analysis of the hFan, a Parallel Hybrid Electric Turbofan Engine [STUB]

NASA and a variety of aerospace industry stakeholders are investing in conceptual studies of electrified aircraft, including parallel hybrid electric aircraft such as the Subsonic Ultra Green Aircraft Research (SUGAR) Volt. At this point, little of the work published in the literature has examined the transient behavior of the turbomachinery in these systems. This paper describes a control system built around the hFan, the parallel hybrid electric turbofan engine designed for the SUGAR Volt concept aircraft. This control system is used to show that the hFan, running with its baseline concept of operations, is capable of transient operation throughout the envelope. The design parameters of this controller are varied to assess the amount of operability margin built into the engine design, and whether this margin can be reduced to enable more aggressive designs, that may feature better fuel economy. Further, studies are performed as parameters for the hFan electric motor are varied to determine how the motor impacts the engine’s need for transient operability margin. The studies suggest that the engine may be redesigned with as much as a 3% reduction in high pressure compressor stall margin. It was also demonstrated that appropriate design and control of the electric motor may be able to buy an additional 0.5% stall margin reduction or a turbine inlet temperature reduction of 35 ̊R, as tested at the sea-level static condition.