Vane position sensor installation within a turbine case

A measuring system for sensing vane positions that comprises a turbine, a target, and a bellows. The turbine includes a plurality of articulating vanes, with each vane being coupled to a sync ring that is configured to position the plurality of articulating vanes in accordance with a degree of rotation by the sync ring. The target is coupled to a first position of the turbine within a first region that is associated with a first vane of the plurality of articulating vanes. The bellows coupled to the turbine and configured to maintain a sensor reference point at a second position. The sensor reference point at the second position is maintained by the bellows in relation to the target at the first position across a gap.

BACKGROUND

The disclosure relates generally to sensing a vane position within a turbine case, and more specifically, to utilizing at least one of multiple sensing technologies installed on the vane platform via bracketing to sense over a gap a vane position.

In general, a jet engine turbine employs a variable cycle technology to synchronously rotate turbine blades to an optimal position, where each optimal position corresponds a maximum engine efficiency with an engine thrust. However, the exact position of the turbine blades is extremely difficult to detect. To date, there are no technical solutions to solve how to precisely monitor the positions of the turbine blades.

SUMMARY

According to one aspect of the invention, a system for sensing vane positions is provided. The system comprises a turbine including a plurality of articulating vanes, wherein each vane coupled to a sync ring, wherein the sync ring is configured to position the plurality of articulating vanes in accordance with a degree of rotation by the sync ring; a target coupled to a first position within a first region of the turbine, wherein the first position is associated with a first vane of the plurality of articulating vanes; and a bellows coupled to the turbine and configured to maintain a sensor reference point at a second position, wherein sensor reference point at the second position is maintained in relation to the target at the first position across a gap.

DETAILED DESCRIPTION

As indicated above, there are no technical solutions for turbine blade position sensing of a jet engine turbine. Thus, what is needed is a system, method, and/or computer program product configured to optimally sense vane positions.

In general, embodiments of the present invention disclosed herein may include a measuring system, methodologies, and/or computer program product that detects and analyzes vane position sensor data acquired from within a high pressure, high temperature zone of a turbine engine (e.g., 1,500 degrees F.). The vane positions are monitored by any one of multiple sensing technologies at the source (e.g., at the actual vane), such that all other error variables and noise contributions in and of the turbine engine are eliminated.

For instance, the multiple sensing technologies are installed using a bellows at the tip of the sensor to ensure an accuracy requirement is met while exposed to various temperature and dimensional instabilities resident in the location of the actual vanes being sense. That is, the bellows negates the effects of thermal and dimensional instabilities. Further, the sensing position is across a gap thru the use of locating a sensor face (or other component) as close as possible to the target located on the vane being measured. The sensor tip is mounted thru a structure or bracket located and supported on the vane platform, which also eliminates the thermal instabilities and limits, to a small amount, the dimensional instabilities. The vane position is then monitored over an angular stroke of 33 degrees thru the use of a wedged target that for every angle of displacement correlates to a point on the wedge angle. The wedge angle is then optimized to establish the accuracy requirement.

For example,FIG. 1illustrates a schematic of a jet engine turbine100. The jet turbine includes a turbine case wall101, a turbine platform102, a crank arm103, a turbine vane104, and a sync ring105. In operation, the jet engine turbine100employs a variable cycle technology to synchronously rotate the sync ring105, which is attached to each turbine vane104via a crank arm103, such that each turbine vane104may be adjusted to an optimal position for greater engine efficiency. For instance, the sync ring105is rotated over an angular stroke of 33 degrees in accordance with locations of a series of targets, where every angle of displacement correlates to a different position of a series of positions for the turbine vane104

Although a jet engine turbine100configuration is illustrated and described in the disclosed embodiment, other engine environments, configurations, and/or machines, such as ground vehicles, rotary aircraft, turbofan engines, high speed compound rotary wing aircraft with supplemental translational thrust systems, dual contra-rotating, coaxial rotor system aircraft, turbo-props, tilt-rotors and tilt-wing aircraft, and the like may also benefit from the embodiments described herein.

FIG. 2illustrates one embodiment of a measuring system200. The measuring system200comprises a sensor sub-system210coupled with the jet engine turbine100. The sensor sub-system210may generally include at least one sensor211, a target212, a channel housing213, a bellows215, and a connector214. The sensor sub-system205is communicatively coupled, as represented by Arrow A, with a computing device210, which may be incorporated with or external to teach other. The measuring system200, the sensor sub-system210, and the computing device220may include and/or employ any number and combination of sensors, computing devices, and networks utilizing various communication technologies, as described below, that enable the measuring system200to perform the measuring process, as further described with respect toFIG. 4

In operation, the measuring system200, which is integral to the jet engine turbine100, as represented by dashed-box, reliably and automatically measures vane position sensor data bases on an orientation between the sensor211and the target212. For instance, the sensor sub-system210senses every angle of displacement by the sync ring105, in accordance with locations of the target212with respect to the sensor211. Each location is then provided as vane position sensor data to the computing device220for further processing. The computing device220then correlates the vane position sensor data to a vane position of the turbine vane104, with an accuracy of 0.5% full scale over the 33 degree articulation angle.

The sensor sub-system210includes at least one sensor211that is operatively coupled to the jet engine turbine100via a bracket and a corresponding target212for each sensor. While the precise location of each sensor211and target212may vary, each combination is associated with one of the articulating vanes so that a stroke at that vane is measured. In this way, when a plurality of combinations are employed, the measuring system200can sense a plurality of vane positions of a plurality of turbine vanes104using a corresponding number of targets212and sensors211.

The sensor211, in general, is a converter that measure physical quantities and converts these physical quantities into a signal (e.g., vane position sensor data) that is sent to the computing system210. Examples of sensing technologies include, but are not limited to microwave sensing, eddy current sensing, capacitance sensing, and inductive sensing. Since the sensor211is located in the high pressure, high temperature zone of the jet engine turbine100, such as where between the turbine case wall101and the turbine platform102, a high temperature sensing can be employed. Further, the sensor211may utilize a sensor reference point to determine an orientation of the target. For instance, if a capacitive sensor is employed, the sensor reference point may be a surface of the capacitive sensor that is maintained at a position inside the high pressure, high temperature zone by the bellows215. In turn, the distance between the surface of the capacitive sensor and the target212will correlate to a position of the turbine vane104. In another embodiment, if a microwave sensor is employed, the sensor reference point may be a component that is maintained at a position inside the high pressure, high temperature zone by the bellows. In this way, the microwave sensor may be placed outside of the high pressure, high temperature zone while detecting the distance between the component and the target212.

The target212is a platform fixed or coupled to a specific location defined during installation of a particular embodiment of the sensor sub-system210. As further described below, the target may be in association with the crank arm103. The target212may include an incline (e.g., a wedge angle used to optimize an accuracy requirement) such that the orientation between the sensor211and the target212changes as the turbine vanes105are articulated. For example, the surface of the incline will alter a gap between a sensor focus of the sensor211, which is on the target212, and the sensor211, as the target212moves along a plane orthogonal to the sensor211. Thus, the vane position may then be monitored over an angular stroke of 33 degrees thru the use of a wedged target that for every angle of displacement correlates to a point on the wedge angle.

The channel housing213is a mechanical unit or tube that may penetrate through a plurality of outer wall of the turbine (e.g., the turbine case wall101) such that a sensor reference point may be inside the high pressure, high temperature zone, while other components are protected from that zone. In this way, rather than utilizing an expensive sensor with a high durability inside the high pressure, high temperature zone, a sensor211may be placed anywhere within or against the channel housing213and still be configured to detect the target212with respect to the sensor reference point.

The connector214is a physical mechanism utilized by the sensor sub-system210to communicate to the computing device220. That is, the connector214may be configured to receive or send signals (e.g., vane position sensor data) to or from the computing device220. An example of the connector214may include any communication interface, such as copper transmission cables, optical transmission fibers, and/or wireless transmission technologies.

The bellows215is a flexible, extensible tubing or way covers used to protect the channel housing and to a pressure seal a hole in the turbine case wall101created by the measuring system200. The bellows215is further configured to maintain a sensor reference point at a position inside the high pressure, high temperature zone above the target212. In this way, a gap is formed between the target212and bellows215. The gap itself changes as the orientation of the target212changes; however, the position of the sensor reference point is maintained. Thus, as the pressure and temperature changes throughout the jet engine turbine100, thereby causing the materials and component of the jet engine turbine100to flex, expand, and contract, the bellows215provides the sensor reference point at a constant position with respect to the target215.

The computing device220includes a processor222, input/output (I/O) interface, and a memory224. The memory224may further store a measuring application230, which includes a module232, and/or a storage database240, which includes data242. The computing device220(e.g., a computing device as described below) is configured to provide a measuring process, where the processor222may receive computer readable program instructions from the measuring application230of the memory224and execute these instructions, thereby performing one or more processes defined by the measuring application230. Also, the computing device100may utilize the storage database240to archive and store signals received from the sensor sub-system210and/or data computed by the measuring application230, as data242. It is to be appreciated that the computing device220is schematically depicted and the location of the computing device220may vary. In particular, the computing device220may be integrated within the sensor sub-system210or may be disposed at a remote location in a wired or wireless communicative state with the sensor sub-system210.

The processor222may include any processing hardware, software, or combination of hardware and software utilized by the computing device220that carries out the computer readable program instructions by performing arithmetical, logical, and/or input/output operations. Examples of the processor222include, but are not limited to an arithmetic logic unit, which performs arithmetic and logical operations; a control unit, which extracts, decodes, and executes instructions from a memory; and an array unit, which utilizes multiple parallel computing elements.

The I/O interface223may include a physical and/or virtual mechanism utilized by the computing device220to communicate between elements internal and/or external to the computing device220. That is, the I/O interface223may be configured to receive or send signals or data within or for the computing device220(e.g., to and from the connector214). An example of the I/O interface223may include a network adapter card or network interface configured to receive computer readable program instructions from a network and forward the computer readable program instructions, original records, or the like for storage in a computer readable storage medium (e.g., memory224) within the respective computing/processing device (e.g., computing device220).

The memory224may include a tangible device that retains and stores computer readable program instructions, as provided by the measuring application230, for use by the processor222of the computing device220.

The measuring application230(“application230”) comprises computer readable program instructions configured to receive and respond to signals from the sensor sub-system210and/or user inputs instructing the application230to operate in a particular manner. The application230includes and is configured to utilize a module232to perform measurement and self-calibrating algorithms during articulation of the turbine vanes104by the sync ring105. The application230takes advantage of greater position accuracy by the sensing sub-system205in accordance with its direct location at the turbine vanes104. In turn, the application203enables greater throttle control, e.g., when an aircraft is performing intense maneuvers, such as carrier landings and short take off and landings. Further, the application230takes advantage of the greater position accuracy by multiple sensing technologies by allowing the selection of a particular sensing technology best suited to meet performance requirements as an overall accuracy budget.

While single items are illustrated for the application230(and other items by each Figure), these representations are not intended to be limiting and thus, the application230items may represent a plurality of applications. For example, multiple measuring applications in different locations may be utilized to access the collected information, and in turn those same applications may be used for on-demand data retrieval. In addition, although one modular breakdown of the application230is offered, it should be understood that the same operability may be provided using fewer, greater, or differently named modules. Although it is not specifically illustrated in the figures, the applications may further include a user interface module and an application programmable interface module; however, these modules may be integrated with any of the above named modules. A user interface module may include computer readable program instructions configured to generate and mange user interfaces that receive inputs and present outputs. An application programmable interface module may include computer readable program instructions configured to specify how other modules, applications, devices, and systems interact with each other.

The storage database240may include a database, such as described above data repository or other data store and may include various kinds of mechanisms for storing, accessing, and retrieving various kinds of data, including a hierarchical database, a set of files in a file system, an application database in a proprietary format, a relational database management system (RDBMS), etc., capable of storing data242. The storage database240is in communication with the application230of and/or applications external to the computing device220, such that information, data structures, and documents including data242may be collected and archived in support of the processes described herein (e.g., measuring process).

As illustrated inFIG. 2, the storage database240includes the data242, illustrated as data242.0to data structure242.n, where ‘n’ is an integer representing a number structures archived by the storage database240. Although one exemplary numbering sequence for the data242of the storage database240is offered, it should be understood that the same operability may be provided using fewer, greater, or differently implemented sequences. The storage database240may generally be included within the computing device220employing a computer operating system such as one of those mentioned above. A data structure (e.g., the individual instances of the data242) is a mechanism of electronically storing and organizing information and/or managing large amounts of information. Thus, the data242are illustrative of sensor outputs, calculation outputs, and historical information that are stored for use by the application230. Examples of data structure types include, but are not limited to, arrays, which store a number of elements in a specific order; records, which are values that contains other values; hash tables, which are dictionaries in which name-value pairs can be added and deleted; sets, which are abstract data structures that store specific values without any particular order and repeated values; graphs and trees, which are linked abstract data structures composed of nodes, where each node contains a value and also one or more pointers to other nodes; and objects, which contain data fields and program code fragments for accessing or modifying those fields.

The measuring system200and elements therein of the Figures may take many different forms and include multiple and/or alternate components and facilities. That is, while the measuring system200is shown inFIG. 2, the components illustrated inFIG. 2and other Figures are not intended to be limiting. Indeed, additional or alternative components and/or implementations may be used. The measuring system200is schematically illustrated in greater detail with respect toFIG. 3.

FIG. 3illustrates a schematic of a sensor sub-system310in accordance with an embodiment. The sensor sub-system410includes a plurality of turbine walls101,307.308, a sensor211, a target212, a channel housing213, a connector214, a bellows215, a sensor reference point316, a bellow shoulder317, a controlled gap349, and a station support350attached to the turbine platform102via support structures354. As illustrated, a station support350enables the bellows215to hover over the target215. The station support350may be configured with at least one support structure354secured to any portion of the turbine, such as the turbine platform102as illustrated. Further, the bellows215may include a spring characteristic that forces the sensor reference point250below the station support350, such that the sensor reference point250and the surface target maintain the controlled gap349. The controlled gap349itself remains at a constant value because the position of the sensor reference point316is maintained by the bellow215, such that as the orientation of the target212changes a position of the turbine vanes104is detected thru the use of a wedged portion of the target (e.g., for every angle of displacement correlates to a point on the wedge angle); however,. Thus, as the pressure and temperature changes throughout the jet engine turbine100, thereby causing the materials and component of the jet engine turbine100to flex, expand, and contract, the bellows215provides the sensor reference point316at a constant position with respect to the target212. In one, embodiment, the sensor211may be positioned at the tip of the bellow, such as with an inductive or capacitive sensor. Note that the channel housing123penetrates through the turbine walls101,307.308, such that a sensor reference point316may be inside the high pressure, high temperature zone, while other components (e.g., such as the connector214) are protected from that zone. Therefore, in another embodiment, the sensor211(e.g., a microwave sensor) may be positioned at an end of the channel housing213opposite the bellows215. In this regard, the microwave sensor may detect the distance between the component, which is at the sensor reference point316, and the target212.

FIG. 4illustrates a process flow400, which may be implemented by any of the measuring systems (e.g.,200) described above. The process flow400begins at block405when the sensor sub-system210via a plurality of sensors211in combination with a plurality of corresponding targets212detects a first set of locations, where each location corresponds to a vane position of a turbine vane105associated with a particular combination. The plurality of sensors then, at block410, output signals to the computing device220for further processing.

At block415, the application230performs signal processing on the output signals to derive the vane position sensor data. Next, at block420, the application220analyzes the vane position sensor data in conjunction with measurement and self-calibrating algorithms. Next, at block425, the application230outputs notifications based on the analysis of the vane position sensor data. In general, the notifications are signals to a control sub-system of the sync ring105that provide feedback for accurately adjusting and/or maintaining the positions of the turbine vanes104via the sync ring105for optimal efficiency of the jet engine turbine100during a corresponding set of flight conditions. In addition, the notifications can be are identifying information (or non-existence of the information) targeted to the systems or users responsible for the aircraft12, so that appropriate maintenance can be performed when, for example, an alignment of the sync ring is incorrect.

The process flow400then proceeds to block430, where the control sub-system adjusts and/or maintains the positions of the turbine vanes104in accordance with the notification of the application230. The process400continues or loops to block405, where the sensor sub-system210via the plurality of sensor/target combinations with detects a second set of locations. In this way, the measuring system can detect immediate positions of the turbine vanes105and also detect over time trends in the jet engine turbine100operations. These trends may then be utilized to predict maintenance and or/failure, which increases the safety and life of the jet engine turbine.

In view of the above, the systems, sub-systems, and/or computing devices, such as measuring system (e.g., sensor sub-system205and computing device210ofFIG. 2), may employ any of a number of computer operating systems, including, but by no means limited to, versions and/or varieties of the AIX UNIX operating system distributed by International Business Machines of Armonk, N.Y., the Microsoft Windows operating system, the Unix operating system (e.g., the Solaris operating system distributed by Oracle Corporation of Redwood Shores, Calif.), the Linux operating system, the Mac OS X and iOS operating systems distributed by Apple Inc. of Cupertino, Calif., the BlackBerry OS distributed by Research In Motion of Waterloo, Canada, and the Android operating system developed by the Open Handset Alliance. Examples of computing devices include, without limitation, a computer workstation, a server, a desktop, a notebook, a laptop, a network device, a handheld computer, or some other computing system and/or device.

Computing devices may include a processor (e.g., a processor222ofFIG. 2) and a computer readable storage medium (e.g., a memory224ofFIG. 2), where the processor receives computer readable program instructions, e.g., from the computer readable storage medium, and executes these instructions, thereby performing one or more processes, including one or more of the processes described herein (e.g., measuring process).

Computer readable program instructions may be compiled or interpreted from computer programs created using assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on a computing device, partly on the computing device, as a stand-alone software package, partly on a local computing device and partly on a remote computer device or entirely on the remote computer device. In the latter scenario, the remote computer may be connected to the local computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present invention. Computer readable program instructions described herein may also be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network (e.g., any combination of computing devices and connections that support communication). For example, a network may be the Internet, a local area network, a wide area network and/or a wireless network, comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers, and utilize a plurality of communication technologies, such as radio technologies, cellular technologies, etc.

Thus, measuring system and method and/or elements thereof may be implemented as computer readable program instructions on one or more computing devices, stored on computer readable storage medium associated therewith. A computer program product may comprise such computer readable program instructions stored on computer readable storage medium for carrying and/or causing a processor to carry out the operations of measuring system and method.