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National Aeronautics and Space Administration
The Application of Hardware in the Loop Testing
for Distributed Engine Control
George L. ThomasN&R Engineering and Management Services, Inc.
Dennis E. CulleyNASA Glenn Research Center
Alex BrandSporian Microsystems, Inc.
July 26, 2016
7/26/2016
Intelligent Control
and Autonomy
Branch
https://ntrs.nasa.gov/search.jsp?R=20170002703 2020-05-01T09:35:12+00:00Z
National Aeronautics and Space Administration
Outline
• Introduction
• HIL Test Implementation
• HIL Test Results
• Ancillary High Bandwidth Pressure Signal Modeling
• Conclusions
• Future Work
27/26/2016
National Aeronautics and Space Administration
Introduction
• Push in industry to meet future design goals (N+2/N+3)
– Fuel economy, noise, emissions
• Research on technologies to meet goals
– Main technologies
• Ultra high bypass
• Hybrid electric
• etc.
– Support technologies
• Distributed engine control (DEC)
• etc.
37/26/2016
National Aeronautics and Space Administration
Introduction
• Distributed engine control (DEC)
– Replaces centralized control (FADEC)
47/26/2016
– Analog wiring lightweight digital bus
• Reduced weight = better fuel economy
• Better scalability, easier certification process and overhauls
– Support advanced control (Active surge / combustion control)
– Electronics limited by high temperature environment!
– Needs different test techniques than centralized systems
Analog
wiring
Bus Short length wiring
and/or electronics
embedded inside
transducers
Smart Nodes
FADEC
National Aeronautics and Space Administration
Intro – How Does DEC Change HIL Testing?
• Testing centralized control
– Just a FADEC and/or analog transducers
• Testing distributed control
– More complicated
57/26/2016
Testbed Machine
FADEC
Smart
Nodes
Testbed Machine
Digital
Bus
National Aeronautics and Space Administration
Intro – HIL Testing of DEC Devices
• Research goals
– Demonstrate modular DEC HIL test techniques and testbed
• Smart sensor via Sporian Microelectronics serves as test case
– Investigate applications of high bandwidth smart sensor
• Active surge/stall control
• Stall precursors are audible Audio range
67/26/2016
• Research tools
– C-MAPSS40k (Distributed)
– DEC System Simulator (DECSS)
• 16 core real-time computer with IO
– Simulation (Sim) Workbench
National Aeronautics and Space Administration
Outline
• Introduction
• HIL Test Implementation
• HIL Test Results
• Ancillary High Bandwidth Pressure Signal Modeling
• Conclusions
• Future Work
77/26/2016
National Aeronautics and Space Administration
HIL Test Implementation
• What is our HIL test?
– Smart P3 sensor in C-MAPSS40k simulation loop running on DECSS
– Replaces C-MAPSS40k Ps3 sensor for feedback
– Test is low bandwidth (signal f < 1/(2TS) ; f < 33.3 Hz)
• Test conditions
– Throttle (PLA) burst and chop (idle to full power and back)
– Sea-level-static (SLS)
87/26/2016
0 5 10 15 20 25 30
40
60
80
Time, [s]
PL
A [d
eg
ree
s]
National Aeronautics and Space Administration
HIL Test Implementation
• HIL Test Loop
97/26/2016
DECSS
Proxy Pressure
Transducer
Analog voltage
representing Ps3
Smart Node
Analog voltage
representing
transducer signal
UDP packets
containing sensed
Ps3 data (including
average, min, max,
and FFT data)
Distributed
C-MAPSS40k
Smart Sensor
National Aeronautics and Space Administration
HIL Test Implementation
• Distributed
C-MAPSS40k
as implemented
on DECSS
• Also shown:
smart sensor
substitutes
simulated Ps3
sensor
107/26/2016
EnginePlant
Model
P2 Sensor
P25 Sensor
P50 Sensor
T2 Sensor
T25 Sensor
T30 Sensor
T50 Sensor
Nf Sensor
Nc Sensor
ControlSystem
Fuel Metering
Valve
Variable StatorVanes
Variable BleedValve
Analog OutputDriver
Ps3 Sensor
Smart Sensor
DECSS
National Aeronautics and Space Administration
HIL Test Implementation
• Sim Workbench
“test” construction
• i.e. Programs and
execution order
for HIL test
117/26/2016
Engine Plant Model
P2 P25
P3
P50 T2 T25 T30 T50 Nf Nc
Control System
Fuel Metering Valve
VariableStator Vanes
VariableBleed Valve
Simulation Inputs[PLA, MN, alt, dTamb]
(C Code)
Set Point =f(PLA, ambient)
P3 Signal Generation
Exec
uti
on
Ord
er
Start of Scheduler Frame
End
SmartNode
National Aeronautics and Space Administration
Outline
• Introduction
• HIL Test Implementation
• HIL Test Results
• Ancillary High Bandwidth Pressure Signal Modeling
• Conclusions
• Future Work
127/26/2016
National Aeronautics and Space Administration
HIL Test Results
• Net thrust, fuel flow, sensed
Ps3, and actual Ps3
– Blue = Baseline (simulation only)
– Red = HIL test (w/ smart sensor)
• Smart sensor Ps3 has 100 ms lag
• Actual and closed-loop response
only change during decel
– Wf/Ps3 (R/U) overestimated
– More conservative limiting
• All limits protected in both cases
137/26/2016
0 5 10 15 20 25 300
2
4x 10
4
Time [s]
Fn
et [
lbf]
0 5 10 15 20 25 300
2
4
Time [s]
Wf [
lb/s
]
0 5 10 15 20 25 300
200
400
Time [s]
Se
nse
d P
s3 [p
si]
0 5 10 15 20 25 300
200
400
Time [s]A
ctu
al P
s3 [p
si]
National Aeronautics and Space Administration
Outline
• Introduction
• HIL Test Implementation
• HIL Test Results
• Ancillary High Bandwidth Pressure Signal Modeling
• Conclusions
• Future Work
147/26/2016
National Aeronautics and Space Administration
Ancillary P3HB Signal Modeling
• Data from literature about stall/surge are often taken with high
bandwidth Kulite sensors, but DC levels and scales not shown
– Limitation of sensors
• Data suggest that pressure disturbances due to blades passing by
stator vanes are picked up and that their magnitude correlates to
compressor stall (and surge often comes after stall inception)
157/26/2016
Compressor stall inception as HPC flow is throttled:
Abdel-Fattah, A. M. and Vivian, A. S., “Development of
the Larzac Engine Rig for Compressor Stall Testing,”
Defense Science and Technology Organization, Victoria,
Australia, DSTO-RR-0377, 2010.
National Aeronautics and Space Administration
Ancillary P3HB Signal Modeling
• Preliminary high bandwidth P3 model added to C-MAPSS40k
• Assumptions– P3HB = Ps3 + blade passing pressure disturbances (BPPD)
– BPPD is sinusoidal, comes from one compressor stage only
– BPPD magnitude is nonlinear, sigmoidal function of HPC surge margin
– BPPD frequency is proportional to HP shaft speed times number of blades in that stage
– All noise in P3HB measurement is lumped together and is AWGN
•
• Goal: HPC SM can be estimated from P3HB measurement
and used for closed-loop surge control
167/26/2016
𝑃3𝐻𝐵 = 𝑃𝑠3 +𝑘2 1 − tanh 𝑘3 ∗ SMHPC − 𝑘4
2∙ cos 𝑘1 ∙ 2𝜋𝑁𝑐 ∙ 𝑡 + N 0, 𝜎2
National Aeronautics and Space Administration
Ancillary P3HB Signal Modeling
• Initial Simulink-only test
(HIL test not performed yet)
– P3HB signal model –
implementation of previous
equation
– BPPD sensor model –
BPPD magnitude recovered
from FFT of sensed P3HB
– HPC SM observer model –
surge margin backed out
from BPPD magnitude
– HPC SM limit logic not shown
177/26/2016
National Aeronautics and Space Administration
Ancillary P3HB Signal Modeling
• Simulink-based simulation
test results
• HPC surge margin limit is protected
• Limiter state chatters on/off
– Can retune
• Response is very slow
– Needs improvement
• Extend to entire flight envelope
187/26/2016
0 5 10 1540
50
60
70
80
PLA
[deg]
0 5 10 150
200
400
Ps3 [
psi]
0 5 10 150
20
40
time [s]HP
C S
urg
e M
arg
in [
%]
0 5 10 150
1
2
3
4
Wf
[lb/s
]
0 5 10 150
0.5
1
BP
PD
[psi]
actual
sensed
National Aeronautics and Space Administration
Outline
• Introduction
• HIL Test Implementation
• HIL Test Results
• Ancillary High Bandwidth Pressure Signal Modeling
• Conclusions
• Future Work
197/26/2016
National Aeronautics and Space Administration
Conclusions
• Demonstrated HIL test of smart P3 sensor on DECSS in
C-MAPSS40k Simulation loop
– HIL test is modular, allows nodes to be added or subtracted from test loop
– Smart sensor works as intended except lag, not characterized yet
• May be due to UDP channel, sensor dynamics, delays in signal generator HW
• P3HB signal model + active surge control models
– Demonstrate potential modeling approach for active surge control
– Need better data for validated empirical model
207/26/2016
National Aeronautics and Space Administration
Outline
• Introduction
• HIL Test Implementation
• HIL Test Results
• Ancillary High Bandwidth Pressure Signal Modeling
• Conclusions
• Future Work
217/26/2016
National Aeronautics and Space Administration
Future Work
• Apply HIL test development techniques to DEC and other problems
• Obtain high quality compressor data to improve model
• Extend active surge control logic to entire flight envelope
227/26/2016
National Aeronautics and Space Administration
Done! Questions?
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