Compact aero-thermo model based engine power control

Patent metadata

Field	Value
Publication number	US-10774749-B2
Application number	US-201816163687-A
Country	US
Kind code	B2
Filing date	Oct 18, 2018
Priority date	Mar 15, 2013
Publication date	Sep 15, 2020
Grant date	Sep 15, 2020

Abstract

Systems and methods for controlling a fluid-based system are disclosed. The systems and methods may include a model processor for generating a model output, the model processor including a set state module for setting dynamic states, the dynamic states input to an open loop model based on the model operating mode, where the open loop model generates current state derivatives, solver state errors, and synthesized parameters as a function of the dynamic states and a model input vector. A constraint on the current state derivatives and solver state errors is based on mathematical abstractions of physical laws that govern behavior of a component of a cycle of a control device. The model processor may further include an estimate state module for determining an estimated state of the model based on at least one of a prior state, the current state derivatives, the solver state errors, and the synthesized parameters.

First claim

What is claimed is:

1. A control system, comprising:
an actuator operable to adjust a control device; and
a computer processor configured to execute a control law to control the actuator as a function of a model output and generate the model output comprising an estimated thrust value for the control device using a model processor, wherein the model processor comprises a plurality of executable instructions to:
process a model input vector and set a model operating mode;
set dynamic states of the model processor, the dynamic states input to an open loop model based on the model operating mode;
generate current state derivatives, solver state errors, and synthesized parameters as a function of the dynamic states and the model input vector, wherein a constraint on the current state derivatives and solver state errors is based on a series of utilities, the utilities based on mathematical abstractions of physical laws that govern behavior of a component of a cycle of the control device, and wherein at least one of the utilities is a configurable utility comprising one or more sub-utilities;
determine an estimated state of the model based on at least one of a prior state, the current state derivatives, the solver state errors, and the synthesized parameters; and
process at least the synthesized parameters of the model to determine the model output.

2. The control system of claim 1 , wherein the control law compares the estimated thrust value with a goal value to determine a thrust control request, the thrust control request received by the actuator to control the thrust of the control device.

3. The control system of claim 1 , wherein the control law applies control error to the estimated thrust signal to account for error in the control device.

4. The control system of claim 3 , wherein the error in the control device is based on at least one of control law error, wear in the control device, customer power extraction, customer bleed extraction, humidity levels, and fuel quality.

5. The control system of claim 1 , wherein the estimated thrust value of the control device is based on, at least, a spool speed of a spool of the control device.

6. The control system of claim 1 , wherein the model input vector includes one or more of raw effector data, boundary conditions, engine sensing data, unit conversion information, range limiting information, rate limiting information, dynamic compensation determinations, and synthesized lacking inputs.

7. The control system of claim 1 , wherein the control device is a gas turbine engine.

8. The control system of claim 7 , wherein the mathematical abstractions of physical laws that govern behavior of the component model a plurality of physical processes associated with components of a thermodynamic cycle of the gas turbine engine.

9. A method for controlling a control device, the method comprising:
generating, by a computer processor, a model output using a model processor;
processing a model input vector and setting a model operating mode;
setting dynamic states of the model processor, the dynamic states input to an open loop model based on the model operating mode;
generating current state derivatives, solver state errors, and synthesized parameters as a function of the dynamic states and the model input vector, wherein a constraint on the current state derivatives and solver state errors is based on a series of utilities, the utilities based on mathematical abstractions of physical laws that govern behavior of a component of a cycle of the control device, and wherein at least one of the utilities is a configurable utility comprising one or more sub-utilities;
determining an estimated state of the model based on at least one of a prior state, the current state derivatives, the solver state errors, and the synthesized parameters;
processing at least the synthesized parameters of the model to determine the model output;
directing an actuator associated with the control device as a function of a model output, the model output comprising an estimated thrust value for the control device, using a control law; and
adjusting the control device using the actuator.

10. The method of claim 9 , wherein the control law compares the estimated thrust value with a goal value to determine a thrust control request, the thrust control request received by the actuator to control the thrust of the control device.

11. The method of claim 9 , wherein the control law applies control error to the estimated thrust signal to account for error in the control device.

12. The method of claim 11 , wherein the error in the control device is based on at least one of control law error, wear in the control device, customer power extraction, customer bleed extraction, humidity levels, or fuel quality.

13. The method of claim 9 , wherein the estimated thrust value of the control device is based on, at least, a spool speed of a spool of the control device.

14. The method of claim 9 , wherein the control device is a gas turbine engine, and the mathematical abstractions of physical laws that govern behavior of the component model a plurality of physical processes associated with components of a thermodynamic cycle of the gas turbine engine.

15. A gas turbine engine comprising:
a fan;
a compressor section downstream of the fan;
a combustor section downstream of the compressor section; a turbine section downstream of the combustor section;
an actuator operable to adjust the gas turbine engine;
a computer processor configured to execute a control law to control the actuator as a function of a model output and generate the model output comprising an estimated thrust value for the control device using a model processor, wherein the model processor comprises a plurality of executable instructions to:
process a model input vector and set a model operating mode;
set dynamic states of the model processor, the dynamic states input to an open loop model based on the model operating mode;
generate current state derivatives, solver state errors, and synthesized parameters as a function of the dynamic states and the model input vector, wherein a constraint on the current state derivatives and solver state errors is based on a series of utilities, the utilities based on mathematical abstractions of physical laws that govern behavior of a component of a cycle of the gas turbine engine, and wherein at least one of the utilities is a configurable utility comprising one or more sub-utilities;
determine an estimated state of the model based on at least one of a prior state, the current state derivatives, the solver state errors, and the synthesized parameters; and
process at least the synthesized parameters of the model to determine the model output.

16. The gas turbine engine of claim 15 , wherein the control law compares the estimated thrust value with a goal value to determine a thrust control request, the thrust control request received by the actuator to control the thrust of the gas turbine engine.

17. The gas turbine engine of claim 15 , wherein the control law applies control error to the estimated thrust signal to account for error in the gas turbine engine.

18. The gas turbine engine of claim 15 , further comprising a spool, wherein the estimated thrust value of the gas turbine engine is based on, at least, a spool speed of the spool.

19. The gas turbine engine of claim 15 , wherein the component comprises an element of at least one of: a duct, a bleed, a pressure loss at a location, a turbine, a compressor, a diffusor, a burner,

Assignees

• United Technologies Corp
• Raytheon Tech Corp

Inventors

• Karpman Boris
• Meisner Richard P
• Donald Matthew
• Case Thomas E

Classifications

• G05B17/02 Primary

  electric · CPC title

• F05D2260/85

  Starting · CPC title

• F04D29/321

  for axial flow compressors · CPC title

• F02C9/16

  Control of working fluid flow (F02C9/48 takes precedence; control of air-intake flow F02C7/057) · CPC title

• F04D29/325

  for axial flow fans (blade mountings F04D29/34, blades F04D29/38) · CPC title