Control of a gas turbine engine
09828869 · 2017-11-28
Assignee
Inventors
- Marko BACIC (Oxford, GB)
- Glenn Alexander Knight (Derby, GB)
- Parag Vyas (Nottingham, GB)
- Sean Patrick Ellis (Derby, GB)
Cpc classification
F01D11/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2270/051
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2270/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D11/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2270/44
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C9/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2270/309
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2270/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2270/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T50/60
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
F01D11/14
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C9/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C9/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A thrust demand signal is provided to a processor of a gas turbine engine and is modified, according to growth time constants of a rotor and/or a casing of the engine, in order to control the rotational speed or the rate of change of rotational speed of the engine so as to prevent contact between the rotor and the casing.
Claims
1. A method of controlling a gas turbine engine, the method comprising: providing a thrust demand signal to a processor associated with the gas turbine engine; modifying the thrust demand signal according to growth time constants of a rotor and/or a casing of the gas turbine engine to control a rotational speed, or a rate of change of rotational speed, of the gas turbine engine to prevent contact between the rotor and the casing; and controlling engine thrust in accordance with the modified thrust demand signal.
2. The method of controlling a gas turbine engine according to claim 1, wherein the processor is one of: (i) an element of a flight management system of an aircraft, and (ii) an element of an auto-throttle.
3. The method of controlling a gas turbine engine according to claim 1, wherein the processor is an element of an electronic engine controller.
4. The method of controlling a gas turbine engine according to claim 1, wherein modifying the thrust demand signal comprises one or both of: applying a delay to the thrust demand signal to allow a gap between the rotor and the casing to be adjusted before a demanded thrust is applied, optionally determining a duration of the delay according to a threshold value of the thrust demand signal; and applying a thrust rate limit to the thrust demand signal.
5. The method of controlling a gas turbine engine according to claim 4, wherein applying the thrust rate limit applies an acceleration modifier to an acceleration schedule set point in an acceleration controller of an electronic engine controller.
6. The method of controlling a gas turbine engine according to claim 4, wherein the gas turbine engine is an aircraft engine and applying the thrust rate limit to the thrust demand signal includes selecting the thrust rate limit according to aircraft and/or engine parameters.
7. The method according to claim 1, further comprising a step of determining whether the gas turbine engine can be operated in: a first mode, in which the thrust demand signal is modified according to growth time constants of the rotor and/or the casing of the gas turbine engine to control the rotational speed, or the rate of change of rotational speed, of the gas turbine engine to prevent contact between the rotor and the casing; or a second mode, in which the gas turbine engine is controlled in accordance with the thrust demand signal.
8. The method according to claim 7, wherein the step of determining comprises operating the gas turbine engine in either the first mode or the second mode in accordance with a schedule based on at least one of: aircraft airspeed, aircraft weight, margin to stall, angle of attack, likelihood of turbulence, a signal from a traffic collision avoidance system, and windshear.
9. The method according to claim 1, wherein the step of modifying the thrust demand signal comprises applying a delay to the thrust demand signal, and/or applying a thrust rate limit having a value in accordance with a schedule based on at least one of aircraft airspeed and aircraft weight.
10. A computer program, having instructions adapted to carry out the method of controlling a gas turbine engine according to claim 1.
11. A computer readable medium, having a computer program recorded thereon, wherein the computer program is adapted to make a computer execute the method of controlling a gas turbine engine according to claim 1.
12. A processor for controlling a gas turbine engine, the processor comprising a signal modifier, wherein: the processor is configured to receive a thrust demand signal; the signal modifier is adapted to modify the received thrust demand signal according to growth time constants of a rotor and/or a casing of the gas turbine engine to control a rotational speed, or a rate of change of rotational speed, of the gas turbine engine to prevent contact between the rotor and the casing; and the processor is configured to control engine thrust in accordance with the modified thrust demand signal.
13. The processor for controlling a gas turbine engine according to claim 12, wherein the signal modifier comprises a delay, which is applicable to the thrust demand signal, and, optionally, a duration of the delay is determined according to a threshold value of the thrust demand signal.
14. The processor for controlling a gas turbine engine according to claim 12, wherein the signal modifier comprises a thrust rate limit applicable to the thrust demand signal.
15. The processor for controlling a gas turbine engine according to claim 12, wherein the signal modifier comprises a delay and a thrust rate limit applicable to the thrust demand signal.
16. The processor for controlling a gas turbine engine according to claim 14, wherein the thrust rate limit comprises an acceleration modifier applicable to an acceleration schedule set point in an acceleration controller of the processor.
17. An aircraft flight management system, comprising the processor according to claim 12.
18. An electronic engine controller, comprising the processor according to claim 12.
19. A gas turbine engine control system, comprising the processor according to claim 12.
Description
(1) Embodiments of the invention will now be described by way of example, with reference to the accompanying figures in which:
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13) The gas turbine engine 10 in
(14) Referring to
(15) In use of the gas turbine engine 10, working fluid (air) does work on the rotor blades 38 as it passes substantially axially through the engine 10. Working fluid that passes over the blade tips 40 through the clearance 44 does no useful work and therefore reduces the efficiency of the engine 10 and increases fuel consumption. However, the clearance 44 is necessary to prevent the blade tips 40 from rubbing against the rotor stage casing 42 which causes damage to one or both components. Tip rub is a transient effect because the rub erodes the blade tip 40 or casing 42 surface which results in the clearance 44 being increased and therefore the engine efficiency reducing.
(16) Additionally the clearance 44 is not constant throughout use of the gas turbine engine 10. Taking the example of a gas turbine engine 10 used to power an aircraft, the rotor stage 34 components grow and shrink in response to centrifugal forces and temperature changes resulting from different engine operating conditions. Thus when the engine 10 is cold, before use, the rotor blades 38 have a defined radial length and the rotor stage casing 42 has a defined diameter and is annular. The components each grow or shrink by different amounts and with a different time constant governing the speed at which the growth or shrinkage occurs. The growth due to centrifugal forces is substantially instantaneous.
(17)
(18) The segment assembly 56 grows radially inwardly whereas the rotor stage casing 42 and disc 52 grow radially outwardly and the rotor blades 38 elongate radially. Thus the clearance 44 reduces during engine acceleration phases of the flight such as ramp-up and the start of take-off. Similarly, the clearance 44 increases during engine deceleration phases. There is a settling period after an engine acceleration or deceleration during which the clearance 44 may fluctuate before settling to a steady-state clearance 44.
(19) Active or passive tip clearance control arrangements may be applied to reduce the variation of clearance 44. For example cool air can be selectively delivered to passages in the rotor stage casing 42 to cool the rotor stage casing 42 and thereby reduce the diameter or retard the growth of the diameter. Alternatively the segment assembly 56 radially inside the rotor stage casing 42 can be moved mechanically to change the clearance 44.
(20)
(21) Line 60 is a typical target clearance without any clearance control. In the taxi phase of a flight the engine 10 is cold and is running at ground idle shaft speeds. Thus the expected clearance is large. In the take-off and climb phases of the flight the engine 10 is run at substantially maximum power demand so the expected clearance reduces significantly. Typically the rotor stages 34 are designed so that the target clearance 60 in these phases is equal to the minimum clearance 58.
(22) In a first cruise phase of the flight the engine power demand is reduced, resulting in the rapid increase in target clearance 60 seen at point 62. The target clearance 60 increases marginally through an extended cruise phase as thrust is reduced in response to the gradually reducing aircraft weight as fuel is burnt. Superimposed on line 60 in
(23) In a step climb flight phase the engine power demand is again increased rapidly and the clearance consequently eroded. Step climb is an example of slam acceleration to maximum climb thrust. The target clearance 60 is generally designed to equal the minimum clearance 58 during step climb. The target clearance 60 during the cruise phase is therefore normally sufficient to allow slam acceleration to maximum climb thrust. A step climb phase is typically followed by another cruise phase in which the target clearance 60 and actual clearance 64 continue from their values before the step climb.
(24) It is beneficial to minimise the area between the target clearance 60 and minimum clearance 58 since this improves the efficiency of the engine 10. A tip clearance control arrangement can be used to control to a target clearance 60 during cruise that equals, or at least approaches, the minimum clearance 58.
(25)
(26) Where a large reduction in actual clearance 66 caused by auto-throttle controlling coincides with errors in tip clearance measurement or estimation and/or with gust loads or similar factors there is an increased risk of tip rub. In particular, a large reduction in clearance as indicated at 68, which significantly exceeds whichever control band 70, 72 is used, may not be controlled quickly enough after the clearance control arrangement is triggered to avoid tip rub.
(27)
(28) Turning now to
(29) The engine controller 88 is configured to receive a thrust demand input signal ThrustD(t) from a flight management system of the aircraft, for example according to the throttle lever angle set by the pilot or a command from the auto-throttle. The engine controller 88 is further configured to provide a fuel flow output signal (not shown) to a fuel metering unit in order to provide the required fuel flow which will accelerate (or decelerate) the engine 10 and produce the level of thrust demanded by the flight management system. In this way the engine controller 88 can maintain engine thrust at a specified level for a given throttle position.
(30) The effect of the thrust rate limiter 86 is to limit the input thrust demand signal ThrustD(t) such that the output thrust demand changes no faster than a specified thrust rate limit. The value of the thrust rate limit is chosen or determined according to the known growth (expansion/contraction) time constants of the rotor stage 34 and/or casing 42 of the engine 10, since the expansion/contraction of the rotor hub 36, the rotor blades 38 and the casing 42 is a function of engine speed and gas temperature. Hence, the thrust rate limit is selected such that the rotational speed and gas temperature of the engine, and therefore the thrust produced, will be adjusted only at a rate which is compatible with the growth rate of the rotor stage 34 and casing 42, so as to ensure that the tip clearance will be sufficient to avoid tip rub even when a rapid increase in thrust is demanded. It will be apparent to the skilled reader that the thrust rate limit may be determined in a number of ways, for example using a look-up table or similar. The thrust rate limit may typically be between 10 and 50 seconds but may take other values as will be understood by the skilled reader.
(31) Optionally, a tip clearance control system of the type discussed hereinabove is used in conjunction with the thrust rate limiter 86 in order to adjust the clearance gap and thereby minimise the delay in the application of the demanded thrust. That is, the tip clearance control system may be employed actively to change the size of the clearance gap as quickly as possible so that the demanded thrust level may be reached more swiftly.
(32) In the embodiment of
(33) In an embodiment which is shown in
(34) In an embodiment which is shown in
(35) In an embodiment, the thrust rate limit is applied to the thrust demand signal ThrustD(t) according to sensed aircraft data such as longitudinal, lateral and vertical accelerations and flight control surface movements, for example as may be encountered in a gust scenario, in order to adjust the acceleration schedule of the engine 10 to match the real state of the aircraft. In an embodiment, the true Mach number of the aircraft is estimated, in a conventional way as will be apparent to the skilled reader, and any gust-induced noise that affects the sensed aircraft data, but which is not of sufficient duration to affect the actual aircraft speed, is smoothed using a model-based filter, such as a Kalman filter or a complementary filter.
(36)
(37) Additionally, the ACU 92 is a slave to the pilot lever angle (PLA) control and runs at a faster rate of computation so there is a combination of delayed/lagged thrust demand and ACU 92 control in the transient detect mode with or without clear air turbulence.
(38)
(39) In an embodiment which is shown in
(40) The effect of applying the thrust delay to the thrust demand signal ThrustD(t) is to provide the tip clearance control system TCC with sufficient time to adjust the tip clearance and so avoid tip rub even when a rapid increase in thrust is demanded.
(41) In the embodiments of
(42) The invention provides that the thrust demand signal ThrustD(t) may be modified using the thrust rate limiter 86 alone, the thrust delay means 94 alone, the thrust delay control means 96 alone, or any combination of the thrust rate limiter 86, the thrust delay means 94, and the thrust delay control means 96.
(43) The skilled reader will appreciate that the flight management system 90 and/or engine controller 88 may be configured to override the thrust rate limiter 86 and/or the thrust delay (control) means 94, 96 in circumstances where a rapid increase in engine thrust is required even at the expense of tip rub, for example during a missed approach or an emergency manoeuvre.
(44)
(45) Thus the invention is based on the realisation that, since there is no mandatory certification requirement regarding the time taken to reach maximum thrust from throttle settings other than flight idle (e.g. cruise), in these circumstances the engine 10 may be automatically controlled to accelerate at a lesser, unconventional rate in such a way as to avoid tip rub and thereby improve fuel efficiency.
(46)
(47) Consequently, the method may comprise controlling the gas turbine engine in accordance with one of a first mode and second mode. When operated in accordance with the first mode, the engine is operated in accordance with the method outlined above, in which the engine is accelerated in accordance with growth time constants of a rotor and/or a casing of the gas turbine engine during cruise, such as by applying a predetermined thrust rate limit or a time lag to the thrust demand signal. When operated in accordance with the second mode, the engine is accelerated directly in accordance with the thrust demand signal. When in the first mode, the turbine target tip clearance can be reduced, thereby saving fuel. When in the second mode, the turbine tip clearance must be maintained at a relatively large clearance in order to accommodate rapid increases in engine thrust.
(48) The engine 10 is operated in accordance with either the first or second mode in accordance with an operating schedule illustrated in
(49) For example, at the start of cruise, where the aircraft is heaviest, the engine may be operated in the second mode at speeds below Mach 0.81, or speeds above Mach 0.88. This is because at these weights, a relatively large amount of thrust is required to attain the necessary acceleration to achieve adequate performance margins. Consequently, it may be unacceptable to delay or restrict engine acceleration. By the end of cruise however, the speeds at which the aircraft can be operated in the first mode has broadened to between Mach 0.72 and Mach 0.88, due to the reduced weight of the aircraft. When operated in this mode, this turbine tip clearance is kept small. At all other operations speeds and weights, the engine is operated in the second mode, and the turbine tip clearance is increased.
(50) Sudden changes between engine operating modes are prevented by providing a transition region within the schedule. Within the transition region, (such as between Mach 0.8 and Mach 0.81 when the aircraft is at the start of cruise), the engine is operated in the first mode, but with either a higher thrust rate limit or a shorter time lag compared to when the engine is operated in the green region. The time lag is modified in accordance with speed in a manner as shown by the “relative gain” section of
(51) Alternatively or in addition, the operating mode may be determined in accordance with flight conditions such as one or more of, margin to stall, angle of attack, likelihood of turbulence, a signal from a traffic collision avoidance system, and windshear. So for example, the aircraft may be operated in the second mode if any of the following conditions are true in addition to the schedule shown in
(52) Furthermore, control of the engine 10 in accordance with the invention may provide a reduction in thermo-mechanical fatigue, since the engine 10 is subjected to fewer rapid acceleration cycles over the duration of its service life.
(53) The control method of the invention may be encompassed in computer-implemented code and may be stored on a computer-readable medium. The invention may thus be a computer-implemented control method and a computer-implemented control system for preventing tip rub in a gas turbine engine, in particular an aircraft gas turbine engine. The computer may be (an element of) an electronic engine controller, for example a full authority digital engine controller (FADEC), including an acceleration control unit, or alternatively may be (an element of) a flight management system or auto-throttle. Advantageously, the control method may be programmed into an existing engine controller, flight management system, or other appropriate computer, i.e. the invention is “retrofittable”.
(54) It will be understood that the invention has been described in relation to its preferred embodiments and may be modified in many different ways without departing from the scope of the invention as defined by the accompanying claims.
(55) Although a three-shaft gas turbine engine 10 has been described the invention is equally applicable to a two-shaft gas turbine engine. As will be apparent to the skilled reader, the invention is felicitous in use for the rotor stages of gas turbine engines used for other purposes than to power an aircraft, for example industrial gas turbine engines or marine gas turbine engines.