FULL-SCALE ENGINE DEMONST H A T ION OF AN A D V A N C E D SENSOR FAILURE D E T E C T ION, ISOLAI ION, 87-2259 AND ACCOMMODAllON ALGOKIlHM - PRFLIMINARY RESULTS
W a l t e r C . M e r r i l l , John C . DeLaat, Steven M. Kroszkewicz , and Mahmood Abdelwahab N a t i o n a l Ae ronau t i cs and Space A d m i n i s t r a t i o n
Lewis Research Center C leve land , Ohio 44135
0 422
A b s t r a c t -
The o b j e c t i v e o f t h e advanced d e t e c t i o n , i s o - l a t i o n , and accommodation (ADIA) program i s t o improve t h e o v e r a l l demonst ra ted r e l i a b i l i t y o f d i g i t a l e l e c t r o n i c c o n t r o l systems f o r t u r b i n e eng ines. For t h i s purpose, a l g o r i t h m s have been deve loped wh ich d e t e c t , i s o l a t e , and accommodate sensor f a i l u r e s u s i n g a n a l y t i c a l redundancy. I n t h i s paper p r e l i m i n a r y r e s u l t s o f d f u l l s c a l e eng ine demons t ra t i on o f t h e ADIA a l g o r i t h m a r e p r e - sented. Minimum d e t e c t a b l e l e v e l s o f sensor f a i l - u res f o r an FlOO t u r b o f a n eng ine c o n t r o l system a r e determined and compared t o t hose o b t a i n e d d u r i n g a p r e v i o u s e v a l u a t i o n o f t h i s a l g o r i t h m u s i n g a r e a l - t i m e h y b r i d computer s i m u l a t i o n o f t h e eng ine .
I n t r o d u c t i o n
The o b j e c t i v e o f t h e advanced d e t e c t i o n , i s o - l a t i o n , and accommodation (ADIA) program i s t o improve t h e o v e r a l l demonst ra ted r e l i a b i l i t y o f d i g i t a l e l e c t r o n i c c o n t r o l systems f o r t u r b i n e eng ines by d e t e c t i n g , i s o l a t i n g , and accommodating sensor f a i l u r e s u s i n g a n a l y t i c a l redundancy methods. T h i s paper d i scusses t h e p r e l i m i n a r y r e s u l t s o f a f u l l s c a l e eng ine demons t ra t i on o f an a n a l y t i c a l redundancy based a l g o r l t h m deve loped as p a r t o f t h e A D I A program.
Over t h e p a s t 35 years hydromechan ica l i m p l e - men ta t i ons o f t u r b i n e eng ine c o n t r o l systems have matured i n t o h i g h l y r e l i a b l e u n i t s . However, t h e r e i s a t r e n d towards i nc reased eng ine c o m p l e x i t y . Th i s i nc reased c o m p l e x i t y i s r e q u i r e d t o meet ever i n c r e a s i n g eng ine per formance requ i remen ts . Conse- q u e n t l y , t h e eng ine c o n t r o l has become i n c r e a s i n g l y complex. Because o f t h i s c o m p l e x i t y t r e n d and t h e r e v o l u t i o n i n d i g i t a l e l e c t r o n i c s , t h e c o n t r o l has evo l ved f r o m a hydromechan ica l t o a f u l l a u t h o r i t y d i g i t a l e l e c t r o n i c (FADEC) imp lemen ta t i on . These FADEC t y p e c o n t r o l s have t o demonst ra te t h e same o r improved l e v e l s o f r e l i a b i l i t y as t h e i r hydro- mechan ica l p redecessors .
I n an e f f o r t t o improve t h e o v e r a l l r e l i a b i l i t y o f t h e d i g i t a l e l e c t r o n i c c o n t r o l system, v a r i o u s redundancy management t echn iques have been a p p l i e d t o b o t h t h e t o t a l c o n t r o l system and t o i n d i v i d u a l components. s t u d i e s 1 have shown t h a t t h e l e a s t r e l i a b l e o f t h e c o n t r o l system components a r e t h e eng ine sensors . I n f a c t some t y p e o f sensor redun- dancy w i l l be r e q u i r e d t o ach ieve adequate c o n t r o l system r e l i a b i l i t y . One i m p o r t a n t t y p e i s a n a l y t i - c a l redundancy (AR) . 2 A n a l y t i c a l redundancy uses a model t o gene ra te redundant I n f o r m a t l o n t h a t can be compared t o measured i n f o r m a t i o n t o d e t e c t f a i l - u res . A n a l y t i c a l redundancy based systems can have c o s t and w e i g h t sav ings over o t h e r approaches such as hardware redundancy.
Cons ide rab le p rog ress has been made i n t h e a p p l i c a t i o n o f a n a l y t i c a l redundancy t o improve t u r b i n e eng ine c o n t r o l system r e l i a b i l i t y . The
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accompl ishments , surveyed i n Ref . 2, p o i n t t o sev- e r a l t echno logy needs. These i n c l u d e : ( 1 ) t h e a b i l i t y t o d e t e c t sma l l ( s o f t ) f a i l u r e s , ( 2 ) r e a l - t i m e imp lemen ta t i ons o f a l g o r i t h m s capab le o f d e t e c t i n g s o f t f a i l u r e s , ( 3 ) a compar ison o f f a i l - u r e d e t e c t i o n a l g o r i t h m c o m p l e x i t y versus pe r fo rm- ance, ( 4 ) a f u l l s c a l e demons t ra t i on o f a s o f t f a i l u r e d e t e c t i o n c a p a b i l i t y , and ( 5 ) an e v a l u a t i o n o f t h e p s e u d o l i n e a r i z e d mode l i ng approach. The ADIA program conducted a t t h e NASA Lewis Research Center addresses a l l o f t hese techno logy needs.
The ADIA program i s o rgan i zed i n t o f o u r phases: development, imp lemen ta t i on , e v a l u a t i o n , and demon- s t r a t i o n . References 3 t o 7 d e s c r i b e t h e deve lop- ment, imp lemen ta t i on , and e v a l u a t i o n phases. I n t h e development p h a ~ e ~ 9 ~ t h e A D I A a l g o r i t h m was des igned u s i n g advanced f i l t e r i n g and d e t e c t i o n me thodo log ies . I n t h e Imp lemen ta t i on phase5 t h i s advanced a l g o r i t h m was implemented i n m ic rop roces - so r based hardware. A p a r a l l e l computer a r c h i t e c - t u r e ( t h r e e p rocesso rs ) was used t o a l l o w t h e a l g o r i t h m t o execu te i n a f rame t i m e c o n s i s t e n t w i t h s t a b l e r e a l - t i m e o p e r a t i o n . I n t h e e v a l u - a t i o n phase6v7 an e v a l u a t i o n o f a l g o r l t h m p e r - formance was o b t a i n e d u s i n g a r e a l - t i m e eng ine s i m u l a t i o n r u n n i n g on a h y b r i d computer. The o b j e c t i v e s o f t h e e v a l u a t i o n were t o ( 1 ) v a l i d a t e t h e a l g o r i t h m f o r sensor f a i l u r e d e t e c t i o n , i s o l a - t i o n , and accommodation (D IA ) e f f e c t i v e n e s s , ( 2 ) document a l g o r i t h m per formance, ( 3 ) v a l i d a t e t h e a l g o r i t h m ' s r e a l - t i m e imp lemen ta t i on , and ( 4 ) e s t a b l i s h a d a t a base f o r t h e demons t ra t i on phase o f t h e ADIA program. T h i s r e p o r t d e s c r i b e s t h e demons t ra t i on o f t h e ADIA a l g o r i t h m on a f u l l s c a l e FlOO eng ine i n t h e NASA Lewis a l t i t u d e t e s t f a c i l i t y .
Th i s paper beg ins w i t h a d e s c r i p t i o n o f t h e t e s t bed system used i n t h e demons t ra t i on o f t h e ADIA a l g o r i t h m . Next , a d e s c r i p t i o n o f t h e ADIA a l g o r i t h m i s g i v e n f o l l o w e d by a d e s c r i p t i o n o f t h e imp lemen ta t i on hardware. The r e s u l t s o f t h e demon- s t r a t i o n a r e t h e n p resen ted . F i n a l l y , conc lus ions and recommendations f o r f u r t h e r work a r e g i v e n .
Tes t Bed System D e s c r i p t i o n
The a l g o r i t h m was demonst ra ted u s i n g a t e s t bed system c o n s i s t i n g o f ( 1 ) an eng ine system, ( 2 ) a m u l t i v a r i a b l e c o n t r o l , and ( 3 ) t h e ADIA a l g o r i t h m . The a l g o r i t h m w i l l be d e s c r i b e d i n t h e n e x t s e c t i o n . The t e s t bed system i s shown i n F i g . 1 .
Eng ine System
The eng ine system c o n s i s t s o f an FlOO t u r b o f a n eng ine and i t s a s s o c i a t e d c o n t r o l a c t u a t o r s and sensors . The FlOO t u r b o f a n eng ine i s a h i g h - per formance, low-bypass r a t i o , t w i n - s p o o l t u r b o f a n eng ine . The t e s t eng ine has f o u r c o n t r o l l e d i n p u t s , f i v e sensed o u t p u t s , and f o u r sensed e n v i - ronmenta l v a r i a b l e s .
These v a r i a b l e s a r e d e f i n e d as f o l l o w s .
C o n t r o l l e d eng ine i n p u t s , Ucom and Um
WF Main combustor f u e l f l o w A F Exhaust n o z z l e a rea C I V V Fan I n l e t v a r i a b l e vanes R C V V Rear compressor v a r i a b l e vanes
Sensed eng ine o u t p u t s . Zm
N1 Fan speed N2 Compressor speed PT4 Burner p r e s s u r e PT6 Exhaust n o z z l e p r e s s u r e F T I l Fan t u r b i n e i n l e t t empera tu re
Sensed env i ronmen ta l v a r i a b l e s , Em
PO Ambient ( s t a t i c ) p r e s s u r e PT2 Fan i n l e t ( t o t a l ) p r e s s u r e TT2 Fan i n l e t t empera tu re TT25 Compressor i n l e t t empera tu re
S t r i c t l y speaking, TT25 i s a sensed eng ine o u t p u t v a r i a b l e . However, s i n c e TT25 i s used o n l y as a s c h e d u l i n g v a r i a b l e i n t h e c o n t r o l ( l i k e TT2), i t i s cons ide red an env i ronmen ta l v a r i a b l e and i s n o t covered by t h e ADIA l o g i c .
M u l t i v a r i a b l e C o n t r o l System
The m u l t i v a r i a b l e c o n t r o l (MVC) system shown i n F i g . 1 i s e s s e n t i a l l y a model f o l l o w i n g , p r o p o r - t i o n a l - p l u s - i n t e g r a l c o n t r o l . The M V C c o n t r o l 8 was p r e v i o u s l y demonst ra ted i n an a l t i t u d e t e s t o f an F l O O eng ine.9 The components o f t h e c o n t r o l a r e t h e r e f e r e n c e p o i n t schedu les , t h e t r a n s i t i o n schedu les , t h e p r o p o r t i o n a l c o n t r o l l o g i c , t h e i n t e g r a l c o n t r o l l o g i c , and t h e eng ine p r o t e c t i o n l o g i c . The r e f e r e n c e p o i n t schedules gene ra te a d e s i r e d eng ine o p e r a t i n g p o i n t i n response t o t h e p i l o t ' s t h r u s t command (PLA) and sensed eng ine env i ronment . The t r a n s i t i o n l o g i c genera tes r a t e l i m i t e d command t r a j e c t o r i e s f o r smooth t r a n s i t i o n between s t e a d y - s t a t e o p e r a t i n g p o i n t s . The p r o p o r - t i o n a l and i n t e g r a l c o n t r o l l o g i c m i n i m i z e t r a n s i - e n t and s t e a d y - s t a t e d e v i a t i o n s f r o m t h e commanded t r a j e c t o r i e s . The eng ine p r o t e c t i o n l o g i c l i m i t s t h e s i z e o f t h e commanded eng ine i n p u t s . The n o r - mal c o n t r o l mode i n t h e MVC l o g i c used f u e l f l o w t o s e t eng ine f a n speed and n o z z l e a rea t o s e t n o z z l e p r e s s u r e ( e n g i n e p r e s s u r e r a t i o ) . However, a t t hose c o n d i t i o n s where l i m i t i n g i s r e q u i r e d , f u e l f l o w can be used t o l i m i t t h e maximum FTIT, t h e maximum PT4, o r t h e minimum PT4.
Demonst ra t ion Hardware --
The ADIA a l g o r i t h m was demonst ra ted u s i n g an F l O O eng ine i n t h e NASA Lewis a l t i t u d e t e s t f a c i l - i t y . T h i s f a c i l i t y can d u p l i c a t e a w ide range o f f l i g h t c o n d i t i o n s ( a l t l t u d e and Mach number). Reference 10 d e s c r i b e s t h e m ic rop rocesso r -based c o n t r o l system computer wh ich implemented t h e MVC and ADIA a l g o r i t h m s , i n c l u d i n g accompanying i n t e r - f ace and m o n i t o r i n g hardware i n t e r a c t i v e d a t a a c q u i s i t i o n s o f t w a r e . A sepa ra te persona l -computer - based system f o r s i m u l a t i n g sensor f a i l u r e s l 1 was used. T h i s f a i l u r e s i m u l a t o r was l o c a t e d between t h e eng ine sensors and t h e c o n t r o l system computer. I t s i m u l a t e d sensor f a i l u r e s by add ing an a p p r o p r i - a t e b i a s v o l t a g e t o t h e s e l e c t e d eng ine sensor
o u t p u t s s i g n a l s . A l l sensor f a i l u r e s ( i . e . , b o t h ha rd and s o f t ) were i n j e c t e d i n t h i s f a s h i o n .
A l g o r i t h m D e s c r i p t i o n
The ADIA a l g o r i t h m d e t e c t s , i s o l a t e s , and accommodates sensor f a i l u r e s i n an F l O O t u r b o f a n eng ine c o n t r o l system. The a l g o r i t h m i n c o r p o r a t e s advanced f i l t e r i n g and d e t e c t i o n l o g i c and i s gene ra l enough t o be a p p l i e d t o d i f f e r e n t eng ines o r o t h e r t ypes o f c o n t r o l systems. The ADIA a l g o r i t h m ( F i g . 1 ) c o n s i s t s o f t h r e e e l e r n ~ n t s : ( 1 ) ha rd sensor f a i l u r e d e t e c t i o n and i s o l a t i o n l o g i c . ( 2 ) s o f t sensor f a i l u r e d e t e c t i o n and i s o l a - t i o n l o g i c , and ( 3 ) an accommodation f i l t e r . Hard f a i l u r e s a r e d e f i n e d as o u t - o f - r a n g e o r l a r g e b i a s e r r o r s t h a t occu r i n s t a n t a n e o u s l y i n t h e sensed va lues . S o f t f a i l u r e s a r e d e f i n e d as sma l l b i a s e r r o r s o r d r i f t e r r o r s t h a t i n c r e a s e r e l a t i v e l y s l o w l y w i t h t i m e .
I n t h e normal o r u n f a i l e d mode o f o p e r a t i o n , t h e accommodation f i l t e r uses t h e f u l l s e t o f eng ine measurements t o gene ra te a s e t o f o p t i m i l e s t i m a t e s o f t h e measurements. These es t ima tes ( Z ) a r e used by t h e c o n t r o l law. When a sensor f a i l u r e occu rs , t h e d e t e c t i o n l o g i c determines t h a t a f a i l u r e has occu r red . The i s o l a t i o n l o g i c t h e n determines wh ich sensor i s f a u l t y . T h i s s t r u c t u r a l i n f o r m a t i o n i s passed t o t h e accommodation f i l t e r . The accommoda t i o n f i l t e r removes t h e f a u l t y measurement f r o m f u r t h e r c o n s i d e r a t i o n . The f i l t e r , however, c o n - t i n u e s t o gene ra te t h e f u l l s e t o f o p t i m a l e s t i m a t e s f o r t h e c o n t r o l . Thus t h e c o n t r o l does n o t have t o r e s t r u c t u r e f o r any sensor f a i l u r e . The A D I A a l g o r i t h m i n p u t s as shown i n F i g . 1 a r e t h e sensed eng ine o u t p u t v a r i a b l e s , Zm, and t h e sensed eng ine i n p u t v a r i a b l e s , The o u t p u t s o f t h e a l g o - r i t h m , t h e e s t i m a t 2 1 t h i t ) . o f t h e measured eng ine o u t p u t s , Z m ( t ) , a r e used as i n p u t t o t h e p r o p o r - t i o n a l p a r t o f t h e c o n t r o l . D u r i n g normal mode o p e r a t i o n , eng ine measurements a r e used i n t h e i n t e g r a l c o n t r o l t o ensure a c c u r a t e s t e a d y - s t a t e o p e r a t i o n . When a sensor f a i l u r e i s accommodated, t h e measurement i n t h e i n t e g r a l c o n t r o l i s r ep laced w i t h t h e co r respond ing accommodation f i l t e r e s t i - mate by r e c o n f i g u r i n g t h e i n t e r f a c e s w i t c h m a t r i x .
Accommodation F i l t e r
The accommodation f i l t e r model a l o n g w i t h a Kaltnan g a i n es t ima tes -o f t h e eng ine s t a t e s o u t p u t s Z as f o l l o w s .
nco rpo ra tes an eng ine u ~ d a t e t o gene ra te
X and t h e eng ine
Here t h e s u b s c r i p t b r e p r e s e n t s t h e base p o i n t ( s t e a d y - s t a t e eng ine o p e r a t i n g p o i n t ) and X i s t h e 4 by 1 model s t a t e v e c t o r , Um t h e 4 by 1 sensed c o n t r o l v e c t o r , and 2, i s t h e 5 by 1 sensed o u t p u t v e c t o r . The m a t r i x K i s t h e Kalman g a i n m a t r i x and y i s t h e r e s i d u a l v e c t o r . The F , G, H, and D m a t r i c e s a r e t h e a p p r o p r i a t e l y dimensioned system m a t r i c e s . T h e i r i n d i v i d u a l m a t r i x elements a l o n g w i t h t hose o f K a r e c o r - r e c t e d by t h e eng ine i n l e t c o n d i t i o n s - Em and scheduled an n o n l i n e a r f u n c t i o n s o f Z . These f u n c t i o n s a r e g i v e n i n Ref. 2.
R e c o n f i g u r a t i o n o f t h e accommodation f i l t e r , a f t e r t h e d e t e c t i o n and i s o l a t i o n o f a sensor f a i l - u re , i s accompl ished by f o r c i n g t h e a p p r o p r i a t e r e s i d u a l e lement t o ze ro . Th i s e f f e c t i v e l y s u b s t i - t u t e s t h e e s t i m a t e f o r t h e feedback (sensed) v a r i - a b l e . For example i f a compressor speed sensor f a i l u r e (N2) has been i s o l a t e d , t h e e f f e c t o f r econ - f i g u r a t i o n i s t o f o r c e y2 = 0. T h i s i s e q u i v a l e n t t o s e t t i n g sensed N2 equal t o t h e e s t i m a t e o f N2 genera ted by t h e f i l t e r . The r e s i d u a l s gen- e r a t e d by t h e accommodation f i l t e r a r e used i n t h e ha rd f a i l u r e d e t e c t i o n l o g i c .
Ha&Failure De&c_tion and I s o l a t i o n Log i c
The hard sensor f a i l u r e d e t e c t i o n and i s o l a - t i o n l o g i c i s s t r a i g h t f o r w a r d . To accompl ish ha rd f a i l u r e d e t e c t i o n and i s o l a t i o n t h e a b s o l u t e va lue o f each component o f t h e r e s i d u a l v e c t o r i s com- pared t o i t s own t h r e s h o l d . I f t h e r e s i d u a l abso l u t e va lue i s g r e a t e r t han t h e t h r e s h o l d , then a f a i l u r e i s d e t e c t e d and i s o l a t e d f o r t h e sensor co r respond ing t o t h e r e s i d u a l e lement . Th resho ld s i z e s a r e i n i t i a l l y de termined f rom t h e s tanda rd d e v i a t i o n o f t h e n o i s e on t h e sensors . These s tanda rd d e v i a t i o n magnitudes a r e then i nc reased t o account f o r mode l i ng e r r o r s i n t h e accommodation f i l t e r . The ha rd d e t e c t i o n t h r e s h o l d va lues a r e t w i c e t h e magni tude o f t hese a d j u s t e d s tanda rd d e v i a t i o n s . These magnitudes a r e summarized I n 'Table 1 .
S o f t F a i l u r e D e t e c t i o n and I s o l a t i o n Log ic -
The s o f t f a i l u r e d e t e c t i o n l o g i c c o n s i s t s o f m u l t i p l e - h y p o t h e s i s - b a s e d t e s t i n g . Each hypo thes i s i s implemented u s i n g a Kalman f i l t e r . The s o f t f a i l u r e d e t e c t i o n / i s o l a t i o n l o g i c s t r u c t u r e i s shown i n F i g . 2. A t o t a l o f s i x hypo thes i s f i l t e r s a r e shown, one f o r normal mode o p e r a t i o n and f i v e f o r t h e f a i l u r e modes (one f o r each eng ine o u t p u t senso r ) . The s t r u c t u r e f o r each hypo thes i s f i l t e r i s i d e n t i c a l t o t h e accommodation f i l t e r . However, each hypo thes i s f i l t e r uses a d i f f e r e n t s e t o f measurements. For example t h e f i r s t hypo thes i s f i l t e r (HI) uses a l l o f t h e sensed eng ine o u t p u t s excep t t h e f i r s t , N1. The second uses a l l o f t h e sensed o u t p u t s excep t t h e second, N2, and so on. Thus, each hypo thes i s f i l t e r genera tes a un ique r e s i d u a l v e c t o r , y i . From t h i s r e s i d u a l each h y p o t h e s i s f i l t e r genera tes a s t a t i s t i c o r l i k e l i - hood based upon a we ighted sum o f squared r e s i d u a l s (WSSR). Assuming Gaussian sensor n o i s e , each sam- p l e o f y i has a c e r t a i n l i k e l i h o o d o r p r o b a b i l i t y .
where k i s a c o n s t a n t and
WSSR 1 = y;Z-'yi
The 61 a r e t h e s tanda rd d e v i a t i o n s d e f i n e d i n Tab le 1 . These s tanda rd d e v i a t i o n va lues s c a l e t h e r e s i d u a l s t o u n i t l e s s q u a n t i t i e s t h a t can be summed t o f o r m WSSR. The WSSR s t a t i s t i c i s smoothed t o remove g ross n o i s e e f f e c t s by a f i r s t o r d e r l a g
w i t h a t i m e c o n s t a n t o f 0.1 sec. M a t h e m a t i c a l l y , when t h e l o g o f t h e r a t i o o f l i k e l i h o o d s i s taken, t hen
The l o g o f t h e r a t i o o f each h y p o t h e s i s l i k e l i h o o d t o t h e normal mode l i k e l i h o o d i s c a l c u l a t e d . I f t h e maximum l o g l i k e l i h o o d r a t i o exceeds t h e t h r e s - h o l d , t hen a f a i l u r e i s d e t e c t e d and i s o l a t e d and accommodation occu rs . I f a sensor f a i l u r e has occu r red I n N1 f o r example, a l l o f t h e h y p o t h e s i s f i l t e r s excep t H1 w i l l be c o r r u p t e d by t h e f a u l t y i n f o r m a t i o n . Thus each o f t h e co r respond ing l i k e - l i h o o d s w i l l be sma l l excep t f o r HI. Thus, LR1 w i l l be t h e maximum and i t w i l l be compared t o t h e t h r e s h o l d t o d e t e c t t h e f a i l u r e .
I n i t i a l l y , t h e s o f t f a i l u r e d e t e c t i o n / i s o l a t i o n t h r e s h o l d was determined by s tanda rd s t a t i s t i c a l a n a l y s i s o f t h e r e s i d u a l s t o s e t t h e con f i dence l e v e l o f f a l s e a larms and missed d e t e c t i o n s . Next , t h e t h r e s h o l d was m o d i f i e d t o account f o r mode l i ng e r r o r . I t was soon appa ren t f r o m i n i t i a l e v a l u a t i o n s t u d i e s t h a t t r a n s i e n t mode l i ng e r r o r was dominant i n d e t e r m i n i n g t h e f i x e d t h r e s h o l d l e v e l s . I t was a l s o c l e a r t h a t t h i s t h r e s h o l d was t o o l a r g e f o r d e s i r a b l e s t e a d y - s t a t e o p e r a t i o n . Thus, an a d a p t i v e t h r e s h o l d was i n c o r p o r a t e d . The a d a p t i v e t h r e s h o l d i s t r i g g e r e d by an i n t e r n a l c o n t r o l system v a r i a b l e wh ich i s I n d i c a t i v e o f t r a n s i e n t o p e r a t i o n . When t h e eng ine expe r i ences a t r a n s i e n t , t h e i s o l a t i o n t h r e s h o l d i s expanded. The e x a c t m o d i f i c a t i o n was found by e x p e r i m e n t a t i o n on a s i m u l a t i o n t o m i n i m i z e f a l s e a larms d u r i n g t r a n s i e n t s . The a d a p t i v e t h r e s - h o l d expans ion l o g i c enab led t h e s t e a d y - s t a t e de tec - t i o n t h r e s h o l d t o be reduced t o 80 p e r c e n t o f i t s o r i g i n a l va lue . A d d i t i o n a l d e t a i l s o f t h e a l g o r i t h m can be found i n Re f . 6.
F a i l u r e Accommodation
For accommodation two sepa ra te s teps a r e t aken . F i r s t , a l l seven o f t h e f i l t e r s ( t h e accommodation f i l t e r and t h e s i x h y p o t h e s i s f i l t e r s ) a r e recon- f i g u r e d t o account f o r t h e d e t e c t e d f a i l u r e mode. Second, i f a s o f t f a i l u r e was d e t e c t e d , t h e s t a t e s and e s t i m a t e s o f a l l seven f i l t e r s a r e updated t o t h e c o r r e c t va lues o f t h e h y p o t h e s i s f i l t e r wh ich cor responds t o t h e f a i l e d sensor .
AOIA A l g o r i t h m I m p l e m e n t a t l o n
To conduct t h e t e s t - b e d demons t ra t i on an imp lemen ta t i on o f t h e ADIA a l g o r i t h m was I n t e g r a t e d w i t h an e x i s t i n g microcomputer imp lemen ta t i on o f t h e F l O O m u l t i v a r i a b l e c o n t r o l (MVC) a l g o r i t h m . The r e s u l t i n g c o n t r o l s microcomputer system was based on t h e I n t e l 80186 m ic rop rocesso r a r c h i t e c - t u r e . To s a t i s f y t h e c o n t r o l update i n t e r v a l r equ i remen t o f 40 msec t o guarantee eng ine s t a b i l - i t y , t h r e e p rocesso rs (CPU1s) o p e r a t i n g i n p a r a l l e l a r e used. Data i s t r a n s f e r r e d between CPU's t h rough d u a l - p o r t e d memory. S y n c h r o n i z a t i o n between CPU's I s ach ieved th rough i n t e r r u p t s .
The e x i s t i n g MVC imp lemen ta t i on was programmed i n f i x e d p o i n t assembly language and was used w l t h - o u t change on CPU No. 1 . The ADIA a l g o r i t h m exe- cu tes on CPU1s No. 2 and No. 3 and was programmed u s i n g f l o a t i n g p o i n t a r i t h m e t i c and FORTRAN. The
t o t a l memory requ i remen t f o r t h e t h r e e CPU's i s 51 Kbytes f o r t h e a l g o r i t h m and 15 Kbytes f o r t h e e x e c u t i v e . I n a l l cases t h e code and c o n s t a n t s were about 65 p e r c e n t and t h e d a t a o r v a r i a b l e s about 35 p e r c e n t o f t h e t o t a l memory r e q u i r e d . A d d i t i o n a l d e t a i l s o f t h e imp lemen ta t i on can be found i n Re f . 6 .
Demonst ra t ion R e s u l t s -. -. - - -. . --
T h i s s e c t i o n d e s c r i b e s p r e l i m i n a r y r e s u l t s o b t a i n e d i n demons t ra t i ng t h e ADIA a l g o r i t h m u s i n g t h e F l O O eng ine. The t e s t p rocedu re and t h e r e s u l t s o f t h e demons t ra t i on a r e d i scussed . The o b j e c t i v e o f t h e eng ine t e s t was t o demonst ra te t h e o p e r a t i o n and per formance o f t h e A D I A a l g o r i t h m and i t s imp lemen ta t i on over a s u b s t a n t i a l p o r t i o n o f t h e f l i g h t enve lope o f t h e F l O O eng ine.
Procedure -
l h e t e s t m a t r i x , shown i n F i g . 3, summarizes t h e t e s t s used t o demonst ra te t h e a l g o r i t h m . The d i f f e r e n t eng ine o p e r a t i n g c o n d i t i o n s ( a l t i t u d e / M a c h number) used f o r t h e demons t ra t i on a r e l i s t e d ac ross t h e t o p o f t h e m a t r i x and t h e d i f f e r e n t t e s t s con- ducted a t t hese p o i n t s a l o n g t h e s i d e . C u r r e n t l y , o n l y r e s u l t s f o r t h e 10 000 f t a l t i t u d e , 0.6 Mach number ( 1 0 K/D.6) o p e r a t i n g c o n d i t i o n have been o b t a i n e d . Eng ine power (PLA) s e t t i n g s were s e l e c t e d which r e p r e s e n t maximum n o n a f t e r b u r n i n g ( i n t e r m e d i - a t e ) t h r u s t (PLA = 80) and -50 p e r c e n t o f i n t e r m e - d i a t e t h r u s t (PLA = 50 and 70 ) . The r a t i o n a l e used t o s e l e c t t h e t e s t m a t r i x o p e r a t i n g p o i n t s was t o d u p l i c a t e as many o f t h e p o i n t s used i n t h e F l O O M u l t i v a r i a b l e C o n t r o l program7 as p o s s i b l e , t o a v o i d h i g h f a n i n l e t p ressu res , and t o reasonab l y span t h e enve lope. T h i s r a t i o n a l e i s a compromise among t a k i n g advantage o f p r e v i o u s r e s u l t s f o r com- p a r i s o n , l i m i t e d r i s k eng ine o p e r a t i o n , and f u l l enve lope v a l i d a t i o n .
The t y p e o f t e s t s used i n t h e demons t ra t i on were s e l e c t e d t o c o m p l e t e l y d e f i n e d e t e c t i o n pe r formance f o r t h r e e common f a i l u r e modes. A l so , t e s t s were conducted t o de te rm ine eng ine c o n t r o l per formance w i t h and w i t h o u t eng ine sensor f a i l - u r e s . The t e s t s a r e summarized i n Tab le 2 .
R e s u l t s
Three t ypes o f demons t ra t i on r e s u l t s w i l l now be p resen ted . The f i r s t shows t h e accuracy o f t h e accommodation f i l t e r w i t h no sensor f a i l u r e s . t h e second shows t h e d e t e c t i o n per formance o f t h e ADIA a l g o r i t h m . F i n a l l y , accommodation per formance i s demonst ra ted.
E s t i m a t o r accu racy . The s i n g l e most i m p o r t a n t element i n d e t e r m i n i n g ADIA a l g o r i t h m per formance i s t h e accuracy o f t h e eng ine o u t p u t e s t i m a t e s used i n t h e a l g o r i t h m . These e s t i m a t e s a r e determined u s i n g t h e accommodation f i l t e r , wh i ch incorporates a s i m p l i f i e d eng ine model. A sample o f t h e accuracy o f t h e f i l t e r i s p resen ted i n F i g . 4 wh ich shows an I d l e - t o - i n t e r m e d i a t e - p o w e r PLA p u l s e t r a n s i e n t gen- e r a t e d a t t h e 10 K/0.6 c o n d i t i o n . The v a r i a b l e s shown, f a n speed ( N l ) and exhaust n o z z l e p r e s s u r e (PT6) , demonst ra te t h e e x c e l l e n t e s t i m a t e accuracy ach ieved . These r e s u l t s a r e t y p i c a l o f t h e o t h e r e s t i m a t e s .
Detec t ion /accommodat ion -. . - - - - -- . . - - per formance. - -. -- l w o types o f sensor f a i l u r e were cons ide red , ha rd and s o f t . Hard f a i l u r e s , because o f t h e i r s i z e , a r e e a s i l y d e t e c t e d . Thus, ha rd f a i l u r e d e t e c t i o n per formance, a l t h o u g h i m p o r t a n t t o system r e l i a b i l i t y , was exam- i n e d a t o n l y one o p e r a t i n g c o n d i t i o n ( 1 0 K/0 .6) . The ADIA a l g o r i t h m exhibited e x c e l l e n t h a r d d e t e c - t i o n per formance a t t h i s c o n d i t i o n . There were no f a l s e a larms o r missed d e t e c t i o n s o f any ha rd f a i l u r e s . Hard f a i l u r e s were i n j e c t e d i n each o f t h e eng ine sensor o u t p u t s i g n a l s . Success fu l d e t e c - t i o n and accommodation o f t h e f a i l u r e was accom- p l i s h e d i n each case. I n a d d i t i o n no f a l s e a larms i n t h e ha rd d e t e c t i o n l o g i c were encountered d u r i n g t h e subsequent s o f t f a i l u r e demons t ra t i on .
S o f t sensor f a i l u r e s , a l t h o u g h sma l l i n magni- t ude , i f unde tec ted may r e s u l t i n degraded o r unsafe eng ine o p e r a t i o n . S o f t f a i l u r e s a r e more d i f f i c u l t t o d e t e c t t hen ha rd f a i l u r e s . T h e r e f o r e t h e demon- s t r a t i o n c o n c e n t r a t e d on s o f t f a i l u r e per formance. Two s o f t f a i l u r e modes were s t u d i e d , b i a s and d r i f t . The c r i t e r i a used t o e v a l u a t e d e t e c t i o n , i s o l a t i o n , and accommodation per formance were: ( 1 ) minimum d e t e c t a b l e b i a s va lues and d r i f t r a t e s , ( 2 ) e lapsed t i m e between sensor f a i l u r e and d e t e c t i o n , ( 3 ) s t e a d y - s t a t e per formance d e g r a d a t i o n a f t e r f a i l u r e accommodation, and ( 4 ) t r a n s i e n t response o f t h e eng ine t o t h e f i l t e r and c o n t r o l r e c o n f i g u - r a t i o n o f f a i l u r e accommodation. The minimum d e t e c t a b l e l e v e l s o f b i a s and d r i f t r a t e o b t a i n e d f o r t h e 10 K/0.6 c o n d i t i o n a r e summarized i n Tab le 3. The minimum d e t e c t a b l e d r i f t r a t e s were determined by a d j u s t i n g t h e d r i f t magni tude such t h a t a f a i l u r e was d e t e c t e d -5 sec a f t e r f a i l u r e i n c e p t i o n .
The demons t ra t i on r e s u l t s a r e compared t o t h e l e v e l s o b t a i n e d d u r i n g t h e r e a l - t i m e h y b r i d e v a l u - a t i o n phase o f t h e program. The comparison a t PLA = 80' shows an e x c e l l e n t agreement f o r b o t h b i a s and d r i f t magni tudes. A t PLA = 50" however, t h e demons t ra t i on r e s u l t s a r e s l i g h t l y h i g h e r t h a n t h e h y b r i d e v a l u a t i o n r e s u l t s . I n t h i s case t h e d e t e c t i o n t h r e s h o l d has been expanded by a f a c t o r o f two t o s tudy t h e d e g r a d a t i o n i n per formance t h l s would cause. I n gene ra l , t h e d e t e c t i o n l e v e l s a r e s t i l l good excep t f o r N1. The a l g o r i t h m was unab le t o d e t e c t a f a i l u r e s m a l l e r t h a n t h e h a r d d e t e c t i o n l e v e l o f 600 rpm.
A d d i t i o n a l l y , d e t e c t i o n per formance f o r sequen- t i a l f a i l u r e s was s t u d i e d . S i x d i f f e r e n t sequences o f s o f t f a i l u r e s were i n j e c t e d i n t o t h e t e s t bed system. One example o f a f a i l u r e sequence was t o f a i l N1, t h e n 4 sec l a t e r f a l l N2, t h e n PT4, and t h e n PT6. I n each case t h e a l g o r i t h m s u c c e s s f u l l y d e t e c t e d and accommodated each sensor f a i l u r e i n t h e c o r r e c t o r d e r . These t e s t s demonst ra te t h e a b i l i t y o f t h e a l g o r i t h m t o c o n t i n u e t o s u c c e s s f u l l y p e r f o r m even a f t e r some sensors have f a i l e d .
F i n a l l y , a s imu l taneous s o f t f a i l u r e o f PT4 and PT6 ( b o t h f a i l e d a t t h e same i n s t a n t o f t i m e ) was i n j e c t e d i n t o t h e eng ine system. The a l g o - r i t h m , a l t h o u g h n o t s p e c i f i c a l l y des igned f o r t h l s ex t reme ly l ow p r o b a b i l i t y even t , s u c c e s s f u l l y d e t e c t e d and accommodated t h l s f a i l u r e s c e n a r i o .
Accommodation per formance. Two exper iments were used t o demonst ra te t h e success fu l accommodation o f
sensor f a i l u r e s . The f i r s t exper iment c o n s i s t e d o f i n j e c t i n g , d e t e c t i n g , and accommodating a s i n g l e sensor f a i l u r e and then commanding a PLA p u l s e t r a n s i e n t . Engine per formance w i t h t h i s accommo dated f a i l e d sensor i s compared t o normal mode eng ine per formance. T y p i c a l r e s u l t s a r e shown f o r t h e PT6 s i n g l e f a i l u r e case f o r f a n speed ( F i g . 5 ( a ) ) and exhaust n o z z l e p r e s s u r e ( F i g . 5 ( b ) ) . Performance was good s i n c e t h e d e s i r e d o r reques t va lues were c l o s e l y m a i n t a i n e d . A s l i g h t d r o p i n a c t u a l P l 6 can be seen b u t t h i s i s a c c e p t a b l e . I n a l l o t h e r cases t h e accommodated s i n g l e f a i l u r e t r a n s i e n t per formance was good.
The second exper iment demonst ra ted t h e e x c e l - l e n t accuracy o f t h e eng ine model. I n t h i s e x p e r i ment, f i r s t a l l t h e eng ine sensors were f a i l e d and accommodated. Then, a PLA p u l s e t r a n s i e n t was genera ted f rom i d l e t o about 7 5 pe rcen t o f f u l l power. R e s u l t s f o r N1 and P l 6 a r e shown i n F i g . 6. Again e x c e l l e n t per formance was demonst ra ted. L i t - t l e o r no ove rshoo t was observed and eng ine s teady- s t a t e per formance was good. T h i s demonst ra tes t h e c a p a b i l i t y o f sa fe , p r e d i c t a b l e eng ine o p e r a t i o n w i t h o u t any eng ine feedback i n f o r m a t i o n over a broad power range.
Conc lus ions - .
Based on r e s u l t s o f eng ine t e s t s ob ta ined so f a r , s e v e r a l p r e l i m i n a r y c o n c l u s i o n s have been reached. F i r s t , i t can be conc luded t h a t t h e ADIA f a i l u r e d e t e c t i o n a l g o r i t h m works q u i t e w e l l . Sen- so r f a i l u r e d e t e c t i o n and accommodation were demon s t r a t e d a t two power c o n d i t i o n s . The minimum d e t e c t a b l e f a i l u r e magnitudes r e p r e s e n t e x c e l l e n t a l g o r i t h m per formance and compare f a v o r a b l y t o v a l - ues p r e d i c t e d by s i m u l a t i o n . Accommodation p e r - formance was e x c e l l e n t . T r a n s i e n t eng ine o p e r a t i o n over t h e f u l l power range w i t h s i n g l e sensors f a i l e d and accommodated was s u c c e s s f u l l y demonst ra ted. Open l oop eng ine o p e r a t i o n ( a l l sensors f a i l e d and accommodated) over 75 pe rcen t o f t h e power range was a l s o demonst ra ted. Second, t h e a l g o r i t h m i s implementab le i n a r e a l i s t i c env i ronment and i n an update i n t e r v a l c o n s i s t e n t w i t h s t a b l e eng ine ope r - a t i o n . O f f - t h e - s h e l f m ic rop rocesso r based hardware and s t r a i g h t f o r w a r d programming p rocedu res , i n c l u d - i n g FORTRAN and f l o a t i n g p o i n t a r i t h m e t i c , were used. P a r a l l e l p r o c e s s i n g was a l s o used and shown t o be an e f f e c t i v e approach t o a c h i e v i n g a r e a l - t i m e imp lemen ta t i on u s i n g o f f - t h e - s h e l f ( c o s t e f f e c t i v e ) computer resou rces . F i n a l l y , i t i s conc luded t h a t t h e demonst ra ted h i g h per formance d e t e c t i o n , i s o l a - t i o n , and accommodation c a p a b i l i t i e s o f t h e ADIA a l g o r i t h m j u s t i f i e s f u r t h e r demons t ra t i on t h roughou t t h e f l i g h t enve lope. Pending t h e a n t i c i p a t e d suc- c e s s f u l outcome o f t h e a d d i t i o n a l demons t ra t i on t e s t i n g , a f l i g h t t e s t e v a l u a t i o n may be j u s t i f i e d as f u t u r e work.
References - -
1. Baker, L.E., Warner, D.E., and D i s p a r t e , C.P., "Des ign o f F a u l t T o l e r a n t E l e c t r o n i c Engine C o n t r o l s , " AIAA Paper 81-1496, J u l y 1981.
2. M e r r i l l , W . C . , "Sensor F a i l u r e D e t e c t i o n f o r J e t Engines Us ing A n a l y t i c a l Redundancy," Jou rna l - o f GuidanceI C o n t r o l and Dynamics, Vo l . 8, No. 6, Nov.-Dec. 1985, pp. 673-682.
3 . B e a t t i e , E.C., Laprad, R . F . , McGlone, M.E., Rock, S.M., and Akh te r , M.M., "Sensor F a i l u r e D e t e c t i o n System - f o r t h e FlDO Turbofan Eng ine, " PWA 5736-17, P r a t t and Whitney Air- c r a f t , East H a r t f o r d , C T , Aug. 1981. (NASA CR-165515 . )
4 . B e a t t i e , E . C . , Laprad, R . F . , Akh te r , M . M . , and Rock, S.M., "Sensor F a i l u r e D e t e c t i o n f o r J e t Eng ines, " PWA 5891-18, P r a t t and Whitney A i r -
H a r t f o r d , CT, May 1983. (NASA c r a f t , East CR-168190.)
5. De laa t , J.C. Implementa t D e t e c t i o n . A l g o r i t h m , " ( A l s o , NASA
and M e r r i l l , W . C . , " A Real-Time i o n o f an Advanced Sensor F a i l u r e I s o l a t i o n and Accommodation AIAA Paper 84-0569, Jan. 1984. TM-83553 . )
6 . M e r r i l l . W . C . , and DeLa t t , J.C., "A Real-Time S i m u l a t i o n E v a l u a t i o n o f an Advanced D e t e c t i o n , I s o l a t i o n and Accommodation A l g o r i t h m f o r Sensor F a i l u r e s i n T u r b i n e Eng ines, " NASA 1M-87289, 1986.
7 . M e r r i l l , W . C . , DeLa t t , J.C., and B ru ton , W . , "Advanced D e t e c t i o n , I s o l a t i o n , and Accommoda- t i o n o f Sensor F a i l u r e s - Rea l -T ime E v a l u a t i o n , " NASA TP- , 1987. (To be p u b l i s h e d . )
8. Soeder, J.F., "F-100 M u l t i v a r i a b l e C o n t r o l Syn thes i s Program - Computer Imp lemen ta t i on o f t h e F-100 M u l t i v a r i a b l e C o n t r o l A l g o r i t h m , " NASA 1P-2231, 1983.
9 . Le th inen , B. , Cos tak i s , W . G . , Soeder, J .F . , and Se ldne r , K . , "F-100 M u l t i v a r i a b l e C o n t r o l Syn thes i s Program - R e s u l t s o f Eng ine A l t i t u d e Tes ts , " NASA TM 5-83367, 1983.
10. DeLa t t , J.C., Soeder, J.F., "Design o f a Microprocessor -Based C o n t r o l , I n t e r f a c e , and M o n i t o r i n g (CIm) U n i t f o r Tu rb ine Engine C o n t r o l s Research," NASA TM-83433, 1983.
11. Melcher , K .J . , DeLaat, J.C., M e r r i l l , W.C. , Ober le , L.G., Schaefer , J.H., and Sad le r , G . G . , "A Sensor F a i l u r e S i m u l a t o r f o r C o n t r o l System R e l i a b i l i t y S t u d i e s , " NASA TM-87271, 1986.
TABLE 1 . - HARD DETECTION
THRESHOLD UAGNITUOES
- PLA
- 50
80
Sensor
F T I T
d e v l a t l o n
Name
TABLE 2. - TEST DEFINITIONS
Sensor f a l l u r e s Hard
S o f t
D r l f t
SSF
PLA t r a n s i e n t s P u l s e
S l n g l e
Open
D e s c r l p t l o n
Large magn l tude ( h a r d ) b l a s f a l l u r e 1s Induced.
Smal l magn l tude ( s o f t ) b l a s f a l l u r e I s l n d u c e d .
Smal l magn l tude ( s o f t ) d r l f t f a l l u r e I s l n d u c e d .
4 sequence o f s u c c e s s l v e sensor f a l l u r e s I s lnduced.
I d l e t o l n t e r m e d l a t e t o I d l e t r a n s l e n t PLA e x c u r s l o n s . The l n t e r m e d l a t e power l e v e l I s m a i n t a i n e d f o r 1 0 sec.
P u l s e t e s t w l t h a s l n g l e sensor f a l l u r e accomnodated b e f o r e l n l t l a t l n g t h e t r a n s l e n t .
Same as t h e P u l s e t e s t e x c e p t t h a t t h e mlnlmum power l e v e l I s r a l s e d s l l g h t l y and t h e maxlmum power l e v e l I s decreased s l l g h t l y and t h e e n g l n e I s c o n t r o l l e d w l t h o u t u s i n g any sensed e n g l n e o u t p u t l n f o r m a t l o n I n t h e c o n t r o l , l . e . , a l l sensors f a l l e d .
TABLE 3. - nINlnun OEIECTABLE BIAS ANO DRIFT FAILURE MAGNITUDES
[ A l t l t u d e = 10 K, Mach = 0.6.1
;ensor IMlnlmum detectable blas f a t l u r e / \ Mlnlmum detectable d r l f t f a l l u r e
s l rnulat lon
N1 300.0 N2 300.0
PT4 12.5 PT6 3.0 FTIT 50.0
N1 -350.0 N2 -350.0
PT4 -12.5 P16 -3.0 FTIT -150.0
Englne lemonstratlon
Hybrld Englne
100.0 200.0 100.0
0.8 0.9 70.0 100.0
IVC ALGORITHM
TRANSITION CONTROL
PROPORTIONAL CONTROL
INTEGRAL CONTROL
ENGINE PROTECTION
AD1 A ALGORITHM
SOFT DETECTION/
F--- l SOLAT I ON LOG I C
I I I I I I
SWITCH M T R I X
I I I I
. . U I
- 4
ACCOMMODATION FILTER - 7 (RESIDUALS)
+ fl I I
I HARD DETECTION/
4 I
I SOLAT I ON LOG I C I I
I I I
FIGURE 1. - FlOO TESTBED SYSTEM.
Wx I MUM LR i
NO NO FAILURE 1 SOLATED
FAILURE ISOLATED
FIGURE 2. - SOFT FAILURE DETECTION/ISOLATION LOGIC STRUCTURE.
189
KEY: P - TESTS COMPLETED
X - TESTS NOT YET COMPLETED
FIGURE 3 . - DEMONSTRATION TEST MATRIX.
- --'--C---
- 'r I ---- SENSED ESTIMTE
- i
4000 (A) FAN SPEED.
3 7 . 5 0 r
TIME, SEC
(B) EXHAUST NOZZLE PRESSURE.
FIGURE 4. - RESPONSE TO A PLA PULSE INPUT - NO SENSOR FAILURES.
(A) FAN SPEED.
T I E . SEC
(B) EXHAUST NOZZLE PRESSURE.
FIGURE 5 . - RESPONSE TO A PLA PULSE INPUT WITH A P T 6 F A I L - URE ACCCMODATED.
-
- I
REQUEST SENSED ESTIHATED
(A) FAN SPEED.
T I E , SEC
(B) EXHAUST NOZZLE PRESSURE.
FIGURE 6 . - RESPONSE TO A PLA PULSE INPUT WITH ALL SENSORS FAILED AND ACCCMODATED.