FADEC Workload Reduction through Standardized Fault Tolerant Smart Sensing Nodes

Present full authority digital engine control (FADEC) systems interface with numerous sensing elements throughout the turbine engine to provide engine control and health management functions. Even though the sensing elements are distributed throughout the turbine engine, the electronic interfaces and the related software are located at the FADEC which increases its computational load. To offload and distribute the signal conditioning, diagnostics, prognostics, and health management functions included in the FADEC, smart high temperature electronics are required that are capable of withstanding the harsh environments at the remote sensor locations. To accomplish this goal, Orbital Research proposes to augment its existing high temperature electronic circuits to include Fault Tolerance, Built-In-Testing, and efficient protocol and prognostic capabilities. These proposed high temperature smart sensor nodes will consist of the following: One or more ASIC chips and high temperature capacitors, resistors and pcb substrates. The Phase I effort identified design changes to its high temperature electronic circuits and showed feasibility of producing a standardized smart interface for a distributed control architecture capable of communicating to the propulsion system controller. In Phase II, Orbital will design, fabricate and perform qualification testing of the smart sensor nodes on engine test stands for a distributed control architecture. BENEFIT: Orbital Research’s role in commercialization will be the identification, design, and development of the enabling high temperature processor and packaging. Orbital will continue to develop and revise the technology for upgrades as demanded for alternative military and civilian applications. Applications include advanced engine and flight controls, unmanned aerial vehicles, and directed energy systems, military control units, actuators, and more-electric systems. Projected civilian applications for the developed control technology include commercial aircraft, ground-based power generation, oil industry, and harsh industrial processing applications. This technology has a wide range of applications in commercial gas turbine engines for aircraft.