Professional Documents
Culture Documents
For health and safety in the workplace you should follow the
regulationslguidelines as specified by the equipment manufacturer,
your company, national safety authorities and national governments.
NOTE
Page
The jet engine relies on the principle of taking in a mass of air and
accelerating it rearwards. This means that according to Newton Laws of
Motion a forward reaction will be produced. The two important laws for a
jet engine are:
Newton's 2nd Law: This states that the force produced is proportional
to the mass times the acceleration and can be
written as:
Now how do these laws help u s with the jet engine - or a propeller for that
matter?
The jet engine causes the air in front of it to be drawn into the intake and
accelerated rearwards via the exhaust. Thus we have "a" in Newton's
second law.
Air has mass (1.2kg for each cubic metre at sea level ISA) so we also have
"m" in the equation F = ma. Thus we have force - BUT it is in the "wrong"
direction - BACKWARDS.
Newton's 3 r d Law states that for every action (the backwards force) there is
a n equal and opposite reaction (a forwards force acting on the engine). So
we have forward thrust.
For a pure jet engine a relatively small mass of air is given a high
acceleration. For a propeller, a large mass of air is accelerated backwards
relatively slowly. A fan engine lies somewhere in between.
To increase the thrust of a jet engine the fuel flow is increased which
increases the engine's rpm. This also applies to a fured pitch propeller
(though these are not usually fitted to turbo-prop engines). For a Variable
Pitch (VP)propeller the thrust can be increased by altering the pitch of the
blades to make the pitch coarser (take a deeper "cut" into the air) - but to
keep the rpm constant the power setting to the engine must be increased -
also increasing fuel burn.
JET ENGINE
INTAKE AIRFLOW
VELOCITY = v rn1s.c
MASS =M kgiml AIRFLOW ACCELERATION = A MASS =M kgiml
REACTION ACTION = F = MA
Fig. 1 THRUST
The air passes to the combustion chamber and heat is added by burning
fuel with a proportion of the air. From the graph (B to C) it can be seen
that combustion takes place at constant pressure so the gas turbine
working cycle is known as a Constant Pressure cycle, or Brayton cycle.
In the combustion chamber the air expands rearwards and the volume of
the gas increases and the gas kinetic energy increases. The gas flow
passes to the turbine section to drive the turbine(s), energy is extracted to
drive the compressor/fan/propeller and the pressure and velocity
decreases.
The gas passes via an exhaust unit to the propelling nozzle, which forms a
convergent duct. The velocity of the gas increases. The reaction to the
high velocity jet produces thrust (C to D). On a turbo-prop engine most of
the thrust energy produced by the gas generator is extracted by the turbine
to drive the propeller.
You should study figure 2 and be able to recall the approximate pressure
and temperature variations from inlet to exhaust.
GRAPH
3
"I
"I
W
(L
LL
COMPRESSION
\
I \
\ \
I \ COMBUSTION
PNEUMATIC INPUT
AUTO CONTROL INPUT
OIL. COOLANT 8
MAINTENANCE T A S K S - ' . . . . ~
PNEUMATIC CONTROL
THRUST
GINE PARAMETERS
TRANSDUCERS
PNEUMATIC 1
ELECTRICAL
FEED BACK TO PILOT AND
HYDRAULIC
AUTO-CONTROL SYSTEMS
OUTPUTS
5. Exhaust. With a pure jet engine the efflux gases should have a
high mass and high velocity. The gases exit the system via a
jet-pipe which may be fitted with a propelling nozzle (a
narrowing of jet pipe a s it gets to the end).
-5-
Combustion Systems
The combustion chamber is double lined with a n inner flame tube and may
be fitted to the engine in one of several arrangements.
In a n Annular system the flame tube and casing are both concentric
continuous structures making up one continuous combustion chamber.
The fuel is pumped from the aircraft fuel tanks (bag type or integral with
the wing structure) by electrically (ac 3 phase, but can be dc) operated fuel
pumps (sometimes called boost pumps). These supply fuel via filters and
shut-off/by-pass valves to the engine driven fuel pump. This pumps fuel to
the fuel control valve which is controlled directly by the flightdeck throttle
lever position or electrical commands from an Engine Electronic Control
(EEC) system or Full Authority Digital Engine Control (FADEC).
The electronic systems get their inputs from the throttle levers of from
auto-throttle computers set by the pilot.
I l l
',!
I
I
5
ENGINE
,,,.----------------------
PRESSURE*
2 ' _--- -- -
TANK
t'. L PUMP
---
I-_
,-----_____
\
SCAVENGE PUMP
Fuel coming from the tank is normally referred to a s low pressure fuel (Ip)
and fuel supplied to the fuel scheduling system from the engine driven
pump called high pressure (hp).
The pumps fitted in the fuel tank are called fuel supply, lp, or in some
cases booster pumps and their purpose is to provide a positive air free
supply to the hp system well above the maximum possible demand for
maximum thrust. This will also prevent flame out of the engine that occurs
when air is allowed to enter the hp system. Additionally, if the engine fuel
scheduling system relied on the engine driven pump to suck fuel from the
tanks it would suffer from severe cavitation, which would lead to excessive
wear of the moving parts. For the same reason, the engine is always shut
down by cutting the fuel supply off near the burners, never by switching off
or isolating the lp system.
The engine driven pumps operate at much higher pressures certainly in the
high hundreds and in some instances in the thousands psig and can be of
the positive displacement, variable swashplate multi-plunger type or, on
the bigger gas turbines, spur gear type pumps. On some fuel scheduling
hp systems there is an additional pump usually referred to as a backing
pump and these can be of the centrifugal or impeller type.
In general the pump will draw oil from the tank through strainers. This
pressure oil then goes to all bearings requiring lubrication passing the
differential oil pressure switch and low pressure warning switch on the
way.
After lubricating the consumer services it is returned via oil coolers, filters
and de-aerators to the tank.
SCAVENGE
OIL COOLER
PRESSURE FILTER
-C--
-8-
Oil systems may be of the following types:
x
Wet Sump System -where the oil is kept in the sump of the
engine.
* Dry Sump System - where the oil is kept in a tank - typical for
most jet engines.
* Pressure Relief Valve System. This system controls the
pressure to the bearings by the use of a spring controlled
pressure relief valve - when operated allows oil directly back to
the tank. The oil supply pressure is not affected unduly by
engine rpm.
%
Full Flow System. For engines where bearing chamber
pressures can be high and the oil pressure has equally to be
high (normally about 40psi or higher). This system dispenses
with the pressure relief valve and allows pressure pump
delivery to supply the consumer services (bearings)directly
allowing increasing pressure with increasing rpm. Fitted to
turbo fan engines. As the oil pressure increases with engine
speed it has to be compared with the air pressure used to seal
the bearing chamber to give the correct readings, hence the
requirement to use a differential pressure sensor.
x
Total Loss System. Sometimes called a n expendable system
and used on engines that run for short periods of time. It is
lighter a s the system requires no return lines, no oil cooler, no
scavenge pumps or filters. After use the oil is ejected into the
gas stream and dumped overboard.
A s the oil pressure increases with engine rpm its pressure has to be
compared with the air pressure used to seal the bearing chambers to give
the correct readings, hence the requirement to use a differential pressure
sensor.
RPM (Revolutions Per Minute). The rotational speed of the engine is picked
up by sensors and fed back to cockpit indicators and engine monitoring
equipment (EECIFADEC) (N1 for a single spool engine, N1 and N2 for a
twin spool and N1, N2 and N 3 for a three spool engine). On triple spool
engines pulse probes are used as the transducers.
ENGINE P R W U TACHOMEIER
TEMPEUTURE
ACCELEROMPIERS
Ph.95 PROBE
AVM SIGNAL
N l S P E W SIGNAL CONDITIONER UNIT
IPMAI
On triple spool engines pulse probes are used. Thrust is indicated by RPM
(Nl)/EPR.
EGT (Exhaust Gas Temperature). Again this data is used for pilot
information and feedback to engine monitoring systems (EECIFADEC).
Torque Transducers. For propeller driven aircraft and for helicopters, these
provide the only true indication of engine output power. For phase
displacement type systems the transducer is fitted a t the power shaft to the
propeller/rotor shaft. For helical gear type transducers they are fitted on
the helical gear in the gear box for helicopters and the reduction gear for
turbo-props.
Pressure. Flow. Quantity. Temperature. Position. These additional
monitoring systems may be found on the engine fitted to equipment such
as:
* Engine oil systems.
* Hydraulic systems.
* Pneumatic systems.
* Fuel systems.
* Thmst reverses.
* VP propeller position
* Motorised valves - position.
Figure 9 shows the sensors as fitted to PW4000 series engines, and figure
10 shows the locations.
ACCELEROMETER
TRANSDUCER
TRANSMITTER
-
Fig. 12 J T 9 D INSTRUMENTATION
TEMPERATURE T2 T3 T l 15 T6 T7
NZ
PRESSURE P1 PZ P3 P4 P5 P6 P7
4 4 4
L.P. H.P. COMBUSTION 4
COHPRESSOR COMPRESSOR' CHAMBERS JET PlPE
4
H.P. T U R B I N E A1
The jet engine can vary considerably in design although they all use the
same basic principle of taking air in via a compressor, mixing it with fuel
and after combustion expelling the products rearwards.
COMPRESSOR
4 AIR OUT
Air is fed through grills into the eye of the compressor then thrown out by
centrifugal force into the combustion chambers. On combustion it
accelerates r e w a r d s to give some of its energy u p to the turbine to drive
the compressor.
In the quest for higher specific fuel consumption figures with increased
power outputs the axial flow compressor was developed (figure 16).This
compressor produces a higher compression ratio with increased efficiency.
HlGH PRESSURE
RATIO AXIAL FLOW
COMPRESSOR STATORS BURNERS
BUSTION SYSiEM
r
HlGH VELOCITY
JET EFFLUX
BEVEL GEAR \
ACCESSORY DRIVE SINGLE STAGE TURBINE
DRIVING COMPRESSOR
\ /
TWO CONNECTING SHAFTS
The three spools allow each to operate at the most efficient speed - it does,
of course, increase manufacturing costs. The fan is driven by the lp turbine
with the ip (intermediate pressure) compressor being driven by the ip
turbine. Speeds (Nl, N2 and N 3 ) are usually picked off by the use of tacho-
probes (pulse type rpm probes).
Some engines have a reduction gearing between the turbine and the fan to
allow the fan to rotate at its optimum speed (figure 20).
LP COMPRESSOR XP COMPRESSOR BYPASS
BEARINGS TURBINE
BEARINGS AIR BEARINGS
/
/ I - .
HP COMPRESSOR
HP TURBINE
(LP COMPRESSOR) CASING FAN CASING
SUPPORTS
NG A 7 STAGE M I A L
D 1 CENTRIFUGAL
ACCESSORYGEA
For turbo prop and helicopter engines a different layout is used. Figure 2 1
shows a direct drive turbo prop configuration. The (in this case) two-stage
turbine drives the compressor and the propeller. Because the engine rpm
would be too high for the propeller it is driven via a reduction gearbox.
In some cases the propeller, or the main rotor drive shaft of a helicopter
(which also drives the tail rotor through bevel gearing), is driven by a
separate set of turbines (a free power turbine). This extracts most of the
energy from the gas stream flow converting it into shaft power (Shaft Horse
Power - SHP). Again a reduction gearbox is used (figure 22).
PROPELLER
/ REDUCTION GEARING
APPROX 10%
-
RESIDUAL
THRUST
The turbine that drives the propeller/rotor head is sometimes called the
Power Turbine and the other turbine/compressor spool is called the Gas
Generator. For best efficiency the majority of the power should be used
across the Power Turbine (free turbine).
PROPELLER DRIVEN BY A FREE TURBINE
COMPRESSOR
DRIVEN BY
TURBINE- \
\
FUEL INJECTOR ROTATING
SLINGER RING
Most engines are now constructed on the modular concept which means
that major components such as the fan, fan casing, compressor
assemblies, turbines etc can be changed a s complete units - in may cases
whilst the engine is "on the wing".
ENGINE SPEED MEASUREMENT
The measurement and indication of engine rpm gives the pilot information
relating to the performance of the engine and a guide as to its power output -
propjet or jet.
Several rpm indication systems are available with the three most common
methods described below. These are:
R E T U R N HAIR S P R I N G
( O n e end attached to instrument case
the other attached to pointer shaft)
\
1ROTATING M A G N E T
FLEXIBLE DRIVE
FROM ENGINE
POINTER R E A D I N G A G A I N S T
A S C A L E C A L I B R A T E D IN
\ 1 COPPERDRAGCUP
\
POINTER S H A F 1
The tachogenerator is basically a rotating field a c generator usually driven off the
compressor rotor via a reduction gearing. The low pressure compressor rpm speed
is known a s NI and high pressure compressor as Nz.The indicator indicates in
percentage rpm. This system is also used for reciprocating engines where the
speed of the crankshaft is measured and indication is in rpm.
The generator's rotating field cuts the stator windings a n d the frequency of the
generator output is proportional to engine compressor or crankshaft rpm.
This signal is passed to the indicator and this is applied to the motor in the
indicator, which is basically a n induction motor with synchronous characteristics.
The signal from the tachogenerator creates a rotating magnetic field in the stator
of the indicator motor. This field therefore rotates a t a speed dependent on
generator frequency and t h u s engine speed.
A s the field rotates it cuts the rotor of the indicator and t h e currents induced
produce a field which interacts with the rotating field, which causes the rotor to
turn.
The rotor h a s a weak permanent magnet and once the rotor i s turning it will lock
on' to the rotating field and behaves a s a synchronous motor. The speed of the
motor is now running a t a speed proportional to the output frequency of the
tachogenerator and therefore engine speed.
The motor in the indicator drives a magnet, which rotates inside a copper drag
cup. The magnet field cuts the copper cup inducing eddy currents into it and
producing a magnetic field, the field from the copper cup interacts with the
magnet field, causing the c u p to rotate in the same direction as the magnet.
The cup turns against the tension of the hairspring until the two forces balance.
The movement of the cup also drives through gearing to position the pointers to
indicate the engine percentage rpm or just rprn in the case of a reciprocating
engine.
Fig. 25 TACH0 GENERATOR & ENGINE SPEED INDICATOR
N2 TACHOMETER
GENERATOR
CENTER INSTRUMENT PANEL
- TRIM TEST
RECEPTACLE
CONTROL CABIN
OTHER
N2 TACHS "E : 8
RIGHT SiDE
,,jj ;
L?
The tachogenerator output is fed to the amplifier in the indicator. Also fed into
the amplifier is a signal from a potentiometer, which is connected to the main
pointer. Thus the two inputs to the amplifier are (1)engine speed and (2) main
pointer position.
If the instrument is indicating the speed correctly then these two signals will be
the same, (the input to the amplifier being the difference between the two signals)
there is no difference therefore and no signal input to the amplifier.
If however, engine speed changes then the input signal from the tacho is not the
same as the feedback pot signal from the main pointer position. This error signal
(difference signal) is fed into the servo amplifier where the increased output is fed
to a motor. The motor drives the indicator and also the digital readout, and as
the indicator is driven the potentiometer output will change and when it equals
the input signal from the tachogenerator, there is no error signal and amplifier
output ceases, the motor stops and indicator shows the new engine speed.
I
.---...---- J
MAIN POWER
C& PAN1
5rlC FEW
ma%runt PMRN
I !
I 4. F R W RESET SWiTCH
The output from the servo amplifier is also fed to a null monitor, the purpose of
which is to detect any failure of the servo circuit to back off the error signal.
In the event that the error signal is not being backed off this de-energises a
warning flag, which drops across the digital counter display. Note that normally
this flag would be energised OFF.
Also on the indicator is an overspeed pointer. This normally sits at the required
position on the indicator. Should an overspeed occur then the main pointer moves
to the position of the overspeed pointer and then a s it exceeds the overspeed
position, it carries the overspeed pointer with it. When the speed is reduced the
main pointer moves downscale but the overspeed pointer remains at the
overspeed position. Reset of the overspeed pointer is achieved by operating a
reset button, which energises a reset solenoid within the indicator.
Maintenance
This is similar to the previous tachogenerator and indicator system, except that a s
a servo indicator is used additional checks would include:
There are various types of these probes, but all work on the same basic principle,
ie a variable reluctance circuit causing a varying magnetic field to induce an emf
in a coil, the frequency of the induced emf being proportional to engine speed.
POLE PIECES
PHONIC
POLE PIECE
OUTER POLE PIECE LASS BOBBIN
EPOXY RESIN
ENCAPSULATION
The probe is located around the circumference of the compressor shaft aligned
with a phonic wheel (integral part of compressor shaft).
When the teeth of the phonic wheel are in line with the pole pieces of the pulse
probe, a path of low reluctance is provided for the magnet's field and a strong field
is created through the coil. However, no emfwill be induced in the coil a s the flux
is steady.
When the wheel moves so the teeth lie between the pole pieces then the reluctance
of the magneticpath h a s increased, therefore the flux h a s decreased but more
importantly changed from a high value to a lower value. A s there is aflwc change
a n emf will be induced into the coil.
As the next set of teeth align with the pole pieces of the probe, then once again
there h a s been a change in reluctance to a lower value and therefore a change of
Jux from a lower value to a higher value so a n emf will be induced into the coil.
The frequency of the induced emf in the coil is proportional to the rate at which
the teeth pass the pole pieces and is therefore directly proportional to the speed of
rotation of the compressor shaft.
Study the drawings and ensure you understand how the systems work.
blank
Fig. 31 NI CRT DISPLAY
DLKAlED W
1UICTlWl BOX
ROWD
DIAL (Y). -CllOSSdLEfD
llESSAGE
READWT (I)
2 5 1 W,
(MI THE 6 R a U D )
PAWETER
READOUT (C)
R
w
- RED
- WHITE
UAXIRU* RED L I N E
EXCEEDANCE READOLIT
( T H I S AREA) (W)
Fig. 35 N3 DISPLAY
If the EICAS should fail then N 1 and N 3 are fed to a Standby Engine Indicator.
This displays the engine parameters on a seven segment LED display, with engine
limits shown to the side of each display. Figure 36 shows the standby indicators
for two and three spool engines.
It displays N1 and N2 %. The N1 actual (green needle) and transient (blue arc)
during autothrust phase. N1 corresponding to lever position (white bullet) and N1
max for the thrust rating obtained if lever is in max take-off position (amber
index).
- D(CIIC W r n O L rCAwms
- N E LW U T m IlfORYAnOY
s FLIT
- -UTS rcrrnw
92,-y-925
I
SEAT B a f S O R l% FEEDC
YO SUOKlY6
Figure 39 shows the engine speed indicating system for the Boeing 777-200
aircraft. The N1 and N2 speed sensors each send three analogue signals. Two
signals from each sensor go to the Engine Electronic Controller (EEC) where it is
changed into ARINC 429 data. The Engine Data Interface Unit (EDIU) sends
ARINC 629 data to the Aircraft Information Management System (AIMS). The N1
and N2 signals are also sent to AIMS, which uses these analogue signals when
there is no digital engine data. Note, as with most modem systems N1 and N2
signals are sent to the Airborne Vibration Monitor (AVM) signal conditioner. The
engine speed data is shown on the EICAS displays.
The N1 speed sensor is a pulse probe, it is about 2 feet (600mm) long and is
positioned a s shown in figure 40.
THRUST REFERENCE
UODE (GREEN1
N l REFERENCE
(GREEN1
ACTUAL N1
IWHtTLI ACTUAL NZ
IYHITEI
NZ REDLINE
LCTUAL NZ
(WHITE I
SEEONDART ENGINE Q l S P L A I
Maintenance Checks
METAL A
METAL B
HOT JUNCTION
1
-
------+
The STAGNATION TYPE thermocouple h a s a large gas entry hole and a small gas
exhaust hole, therefore the gas is slowed down or STAGNATED to allow the
thermocouple to sense the temperature. These types would be used i n pure jet
engine systems (high gas velocity).
HOUSiNG
INSULATOR
GAS OUT
THERMOCOUPLE
d
GAS IN
- 35 -
Fig. 45 RAPID RESPONSE TYPE THERMOCOUPLE
THREE
THERMOCOUPLES
The RAPID RESPONSE TYPE h a s gas exit a n d entry holes of equal size and are
opposite each other, this type is used on lower exhaust gas velocity engines, eg
turbo-prop engines.
Actual types of thermocouple vary so check the aircraft you are currently working
on. It should also be realised that the probe may contain one, two or three
elements to feed EGT to other systems, eg top temperature control.
_.--._
The thermocouples and their leads are in a harness assembly around the engne
and the number of probes depend on the engine. The leads going from the
junction box to the indicator will be Alumel and Chrome1 (although this may not
always be the case). The indicator is a moving coil millivoltmeter calibrated in
degrees centigrade.
Some systems may include a trimmer resistor. One such type is made up of a wire
wound on a spool or bobbin connected in the leads to the indicator. Its purpose is
to allow adjustment of the overall circuit resistance. Measurement is taken from
the indicator terminals (disconnected)back through the system. Typical values for
earlier systems would be 8R or 25R. If incorrect then the correct amount of wire
on the bobbin would have to be cut off to bring the resistance value to within the
specified values.
,N,ZRWErnTE ,",,C,,ON
sox ,"~nt"oco"~Lz
The resistor is across the thermocouple output to load' the output and divert the
excessive current to enable the indicator to read accurately. The value of the
resistor will vary from engine to engine and is usually recorded on the engine data
plate and also in the engine log book. The resistor, if fitted, must be removed with
the engine.
If the leads from the engine to the indicator are made of the same material as the
thermocouples, these are known as EXTENSION LEADS.
On some aircraft the leads from the engine to the indicator are not made of the
same material as the thermocouples, eg Chromel/Alumel thermocouples might
have Copper/Constantan leads to the indicator, these leads are known as
COMPENSATING LEADS.
It might be considered that the compensating leads may not work as effectively as
they create another thermocouple at the connections. However, the two
combinations are compatible and it works well.
If we assume that the cold junction is maintained at OC and the hot junction is
500C then as the temperature difference between hot and cold junctions is 500C
the indicator will read 500C (20.64 mV generated).
One method employed is to use a bimetallic strip within the moving coil indicator.
POINTER %
SPRING~AB-
WASHER
COIL IAll I
COIL AlTACHMENl
LOWER SUPPORT TAG (LOWER)
BRACKET
IlPPFR
. .
HAIRSPRING
TAB WASHER
_ CONTACT TAG
INSULATING BUSH /
A n
JE\NEL BEARING
INSULATING WASHER LOCK NUT
Assume now that the situation was a s before, ie cold junction temperature
increased by 20C. Previously the indication would have gone down scale, but
now the bimetallic spring (figure 51) will unwind to oppose the movement
downscale. The spring causes the hairspring to move and maintain the pointer at
the upscale position, the indicator therefore reads the true hot junction
temperature of 500C.
A s the temperature changes at the indicator this will also effect the resistance of
the moving coil itself. If the temperature goes up, its resistance goes up and the
current through it falls and therefore the indication will fall. One method of
overcoming this problem is to connect a thermistor in series with the indicator
coil. A thermistor has a negative temperature coefficient, ie its resistance
decreases with an increase in temperature. If the temperature of the indicator
increases then the coil increases its resistance, the thermistor resistance
decreases, so the overall resistance of the coil circuit remains the same. Therefore
current and indication will remain the same.
l
a --.--
EUREKA
SHUNT
INDICATOR
i i
Fig. 52 COMPENSATION FOR COIL RESISTANCE
CHANGE USING A THERIMISTOR
The input to the amplifier is the thermocouple signal and an indicator position
feedback signal, any difference between these two signals creates an error signal
which is amplified and fed to a servomotor. This drives the indicator pointer and
counter via the gear train.
The gear train also drives the balance potentiometer to provide a feedback signal
to the amplifier and servomotor until the input signals are equal and motor stops
to indicate the new EGT.
If EGT exceeds the operating limit the amber overtemp light illuminates - this is
operated by a snap action cam actuated switch. In addition the engine over
temperature condition is indicated by the maximum indication pointer. If the
EGT exceeds the limit the main pointer will carry the maximum indication pointer
to a higher value on the scale and when the EGT lowers the maximum indication
pointer remains at the over temperature reading. This pointer is reset by a reset
switch.
If a circuit malfunction occurs the Integral Integrity Monitor (IIM) causes the
failure flag circuit to de-energise and the failure flag will fall in front of the
numerals. Pointer and counter remain at the last value before failure occurred
The instrument dial is illuminated using 5 volts ac.
Figure 53 shows a typical EGT system and figure 54 shows the layout of the
thermocouple system on a Boeing 737-400 series aircraft.
Fig. 54 THERMOCOUPLE HARNESS ON A BOEING 737-400
GASEXHAUST
CHROME~ALUMEL
THERMOCOUPLE TIP
4I
GAS INLET
Figure 54 shows a 9-probe system, with a typical probe being shown in figure 55.
The signal from the thermocouples is fed into the display unit. The input signal is
amplified and cold junction compensation is carried out and then fed to a voltage
to frequency conversion module, which produces an output frequency
proportional to the dc input signal. The frequency is digitised, formatted and
stored in a RAM in readiness for transmission to the display driver and then to
the LED display.
Fig. 56 EGT INDICATING SYSTEM
- 44 -
Figure 57 shows the general layout of a seventeen probe system on a large
aircraft and figure 58 shows the CRT display. Study the drawings and make sure
you understand the general operation of the system.
Some probes may contain more than one junction. Figure 59 shows a probe with
two junctions, referred to as a 'short reach' and long reach' probe from the extent
to which they reach into the gas stream.
HARNESS
CONNECTION
u
OUNTING
ANGE
Figure 60 shows an EGT display, which has a dc servo driven pointer and also an
LED display.
Fitted to some aircraft, the system uses a radiation pyrometer. The basic system
is shown in figure 6 1.
With reference to figure 6 1. The pyrometer sensing head is mounted so that the
line of sight of the lens is on the turbine blades. The detected radiation is sensed
via a sapphire or silica lens to focus the energy onto the end of the fibre optic
assembly. The fibre optic link transmits the radiated signal a s a n optical signal,
which is sensed by a silicon photocell within the detector, amplified and fed to the
indicator or control box of the system.
The two thermocouples send analogue signals to the Engine Electronic Control
(EEC). The EEC sends digital signals to the AIMS (via EDIU and ARINC 629
buses) for display and monitoring. The pyrometer sensor signal is sent via the
fibre optic cable to a n electronics module, the EEC again sends signals to the
AIMS for display and monitoring functions. The EGT indication is shown on the
EICAS display.
Maintenance Procedures
It is important that you study the appropriate AMM for the aircraft you are
currently working on. Use the following notes a s guidelines only.
Visual Checks
System Tests
Note. It is important that you know whether the test set you are using
h a s automatic ambient temperature compensation or not, if not then
allowance must be made for the ambient temperature.
5. Failure Flag - tripping and resetting the circuit breaker to ensure flag
appears and disappears correctly.
The thrust produced by a jet engine does not vary in direct proportion to turbine
rpm. The thrust ratings are calculated in such a way that they must be corrected
for variations in temperature and pressure at the compressor intake. Since
compressor intake pressure is related to the outlet pressure at the turbine, then
the thrust is more accurately determined by measuring the ratio between these
two pressures. The Engine Pressure Ratio system is therefore a thrust indication
system for these types of engine. The ratio provided by this system is therefore:
The basic components of the system are an inlet pressure sensing probe, exhaust
pressure sensing probes, EPR transmitter and EPR gauge. There are variations
between aircraft in design, operation and location of components, particularly the
operation of the EPR transmitter. We shall look at one typical system.
The engine inlet pressure is sensed by a probe similar to a Pitot probe and is
located at or near the front of the engine, in the intake or in the intake cone. It
will sense Pitot pressure (P2)and transmit this to the EPR transducer.
The engine exhaust pressure (P7)is sensed by a number of probes located within
the exhaust pipe. In the system described there are six disposed radially in the
turbine exhaust case.
EPR Transmitter
These vary in operation. However, their basic function is to convert the ratio of
outletlinlet pressure to an electrical signal for transmission to the indicator.
EPR Indicator
INOiCdTOR
/-_--
ENGINE CHANCE CISCONNECT
ICE DETECTION
T CONNECTIONS
I 11.8V 400Hz
L----
OUTPUT
System Operation
The inlet pressure (PT?)is fed to two of the bellows in the transmitter/transducer,
and exhaust pressure (PT~) is fed to one of the other bellows with the fourth bellow
evacuated and sealed (Pv).
With constant EPR the transducer is in a state of force balance and no movement
occurs. When there is a change in EPR, out of balance forces result in movement
of the bellows system and the LVDT (Linear Variable Differential Transformer).
This gives a n electrical output to a n amplifier whose output signals a servomotor
control winding: The servomotor moves and drives the bellows system which
nulls the output of the LVDT. It also drives the control transmitter rotor (CX).
The output from the CX is transmitted to the CT in the indicator. The output from
the CT rotor is amplified and fed to a motor. The motor drives (through a gear box)
the EPR pointer and digital counter and the CT rotor to the null position. At this
position the system will be in equilibrium and the EPR indicator now shows the
new reading.
Maintenance Checks
The instrument should be reading 1.OO on the ground with engine not running.
Indicator. Check for security, damage and legibility of markings. Check the
function of the lighting and power failure flag operation. Check pointer position
and check operation of reference setting knob together with reference indication.
System Checks
These usually consists of (i) a leak check and (ii)an accuracy test.
Leak Test Connect up EPR test set, apply inlet and exhaust
pressures as stated in the AMM. Maximum permissible
drop is 0.25 in Hg in 5 minutes.
EPR Biasing
On some systems the electrical signals generated by the EPR transmitter are
biased by a control differential transformer synchro (CDX)fitted between the
control transmitter synchro in the transmitter and the control transformer
synchro in the indicator (figure 68).
The amount of bias required from the CDX is calculated and entered on the
engine data plate and in the engine log book and engine test records.
When the engine is fitted to the airframe the correct CDX with the correct bias is
fitted into the system iaw the AMM and the engine data plate.
I
j15VAC
I BUS N O 1
P6 MAIN POWER
CIRCUIT BREAKER
-I
PANEL
Used on multi spool engines the Integrated Engine Pressure Ratio system uses the
ratio of integrated engine exhaust pressure to air intake pressure to provide an
indication of engine thrust on the flight deck (figures 69 and 70).
The integrated engine exhaust pressure uses signals from both the hot and cold
thrust streams and also the engine intake pressure. These are fed to a transmitter
from which electrical signals are passed to the flight deck indicator and displayed
as units of EPR. Components of an IEPR system include:
* One inlet pressure probe (PI)located in the engine nose cowl on wing
mounted engines, and in the centre of the intake on the rear engine.
* Three anti-iced low-pressure (LP)fan pressure rakes (PF),one located in
the splitter leading edge and one located on each of the A-frame structures.
* Five high-pressure (P8)rakes located in 4 of the 18-rotor tail bearing
supports.
x
One integrating multiple connector for PF and P8 pressures.
* One pressure ratio transmitter, similar in construction and operation to that
previously described.
* One Trimmer Unit.
* One EPR indicator mounted in the flight deck.
LP TURBlNE BEARING
TRANSMITTER
A signal of air intake pressure (PI),tapped from the sensing probe supply, is fed
to the IEPR transmitter. Signals of LP compressor exhaust pressure (PF) and gas
generator exhaust pressure (Pa),sensed by the rakes, are fed to the multiple
connector where they are integrated and the resultant pressure (P-INT)passed to
the transmitter., The transmitter converts the pressure signals to an electrical
signal, which is fed to a trimmer unit and then to the indicator. The function of
the trimmer unit is to reduce scatter in the relationship between indicated EPR
and engine thrust so that it is unique for all engines.
Finally, the electrical signal, together with a fured dc reference voltage, is fed to
and processed by the EPR indicator to provide both a n analogue and digital
display in units of EPR.
PF RAKES
Figure 71 shows an EPR system using a digital transmitter and CRT display.
The engine inlet pressures (Pl)and Pf (fan exhaust pressure) are transduced by
two vibrating cylinder pressure transducers, which produce frequencies
proportional to the air pressures. These signals are fed to a microprocessor which
converts them into the ratio PI/Pl and digitises them for transmission to the
EICAS computers and then to the CRT display.
l----l
DATA ACPU1SITION
I n earlier systems, hydraulic, fuel, oil and pneumatic pressures were fed directly
to a Bourdon tube type gauge on the flight deck. This meant long pressure lines to
the flight deck with a consequent weight penalty, increased leak probability and
(for pneumatic pressures) a safety issue.
INSTRUMENT CASE
PRESSURE
CONNECTION
7
-
R :
&LINK
:
- :
TO QUADRANT
QUADRANT GEAR 8.
DwvE si+An
- 57 -
The Bourdon Tube Pressure Gauge
The bourdon tube is a metal tube with an elliptical cross-section shaped in the
form of a C. The tube material may be phosphor bronze, beryllium bronze or
beryllium copper. One end of the tube is sealed and the other is open to accept
the pressure.
PRESSURE
There is usually a choke or restrictor fitted to the inlet union to prevent surge
pressures affecting the gauge. The principle of operation is such that when
pressure is applied to the interior of the tube there is a tendency for the cross
sectional area of the tube to attempt to change its shape to a more circular cross-
section, the tube tries to straighten its arc, causing the sealed end to move
outwards and move the gear and thus the indicator needle.
To prevent total fluid loss from the main system should the supply line to the
flight deck fail some fluid lines had a pressure transfer valve fitted which transfers
pressure but not flow. It consisted of a small cylinder in which slid a piston with
the system connected to one end of the cylinder and the pressure transfer pipe to
the flight deck fitted to the other. As the system pressure changed so the piston
would move and transfer the pressure to the flight deck supply line. If this line
leaked then the piston would move to the limit of its travel (2 or 3 cms) with no
fluid loss from the system. The pressure indication would go to zero.
400Hz
PLY
PRESSURE
GWRBOX
FLIGHT DECK GAUGE
2 PH&E MOTOR
Pressure causes the bourdon tube to move and the CX rotor to turn. This causes
a change of field across the CT rotor, inducing an error voltage. This voltage is
amplified and sensed for direction and then fed to a 2-phase servomotor, which
drives the indicator and also the CT rotor. When the rotor reaches its NULL
position, ie field cutting it at 90, there is no error signal induced and the motor
stops. The gauge now showing the system pressure.
The components of the system are an oil pressure transmitter and indicator. The
transmitter has a diaphragm, one side of which is connected to engine oil
pressure and the other side is connected to ambient pressure. The pressure
difference positions the diaphragm and therefore the rotor of the TX (Torque
Transmitter). In the indicator is a TX synchro and in the transmitter is a TR
(Torque Receiver) synchro. This means that the normal torque synchro action will
take place and the TR rotor in the indicator will move to the same position as the
TX rotor and drive the pointer of the pressure indicator.
ING NO. 2
1BV AE
IUI NO. I
(EN0 NO. I
Y8VAC
Maintenance Checks
Visual Checks These are similar to the checks carried out on previous
systems.
Another system used for measurement and indication of oil pressure is a system
which uses the ac ratiometer principle. The system consists of a n INDUCTOR
PRESSURE TRANSMITTER and an ac RATIOMETER INDICATOR.
The pressure transmitter (figure 76) receives the oil pressure through the oil inlet
in the base of the transmitter into the bellows. The bellows expand and causes
the armature spindle to move, this causes the two soft iron armature cores to
move in relation to the stationery stator windings. A s these windings are fed with
ac, the inductance of the windings will change. The cores are displaced such that
as one core is moving into a winding the other core is moving out of its winding.
The inductor (indicator) consists of a single shaft on which there are three discs,
two snail or cam shaped and one circular. When the shaft rotates all the discs
rotate in the same direction. The two cam shaped discs each rotate between the
poles of their respective Shaded Pole Motor. An important point to note is that the
discs have their cams handed from one another, ie as one disc presents a smaller
area in between its motor's pole pieces the other disc presents a larger area
between its motors pole pieces. The circular disc at the end of the shaft rotates
between the poles of a magnet to provide damping.
OVERLOAD STOP
SPRING ADJUSTER
ARMATURE
SPINDLE GUIDE
INLET
- 61 -
LAMINATION & BOBBIN
ASSEMBLIES
CAM SHAPED
SHADING
RINGS
Operation
The cores in the transmitter wili be at certain positions with regards to the stator
windings. Coil 'A' supplies motor 'A', coil 'B'supplies motor 73' and the current
supplied to these motors depends on the inductance of the stator windings
(position of core relative to stator winding). The input supply is 26v 400 Hz single
phase.
The current supplied to each motor produces alternating fluxes across the pole
pieces, the presence of the shading ring around each pole piece causes a flux lag
between the shaded and unshaded portion of the pole pieces and therefore two
out of phase fluxes across the gap between the pole pieces. These fluxes cut the
disc and produce eddy currents. The field produced by the induced eddy currents
interacts with the field between the pole pieces causing the disc to turn.
The effect of motor 'A' is to drive its disc clockwise and in motor 'B' to drive its disc
anti-clockwise.
PRESSURE
INDUCTOR COILS
/
Wound around the
soft iron cores
,
DIRECTION OF
BELLOWS RESTRAiNING MOTOR DRIVE A
SPRING
DAMPING DISC
REMOVED FOR
CLARITY
TRANSDUCER INDICATOR
Therefore when the pressure is steady the torque on disc 'A' is exactly balanced by
the torque on disc 73' (ratiometer principle).
Assume now a n increase in pressure. Coil 'B' inductance will increase (core moves
into winding and increases the flux density) and coil 'A' inductance will decrease
(core moves out of winding). The current to motor 'A'will increase and the current
to motor 73' will decrease. The torque on the discs is no longer equal and motor
'A' torque will increase and motor 'B' will decrease.
The shaft and all the discs will now rotate clockwise and as it rotates the disc area
presented between the poles of motor 'A' will decrease (with torque decreasing, as
the area presented between the poles must have an effect on torque produced)
while the area of the disc presented between poles of motor 'B' will increase. It is
being dragged Backwards' (torque increasing).
At some point the torques will balance and the shaft, discs and pointer will
become stationary at the new pressure reading.
The hairspring brings the pointer 'off scale' in the event of power failure.
The transmitter signals may be sent direct to computers, such as the EICAS
computers and then fed to the CRT display (figure 81).
Fig. 79 A MORE REALISTIC AC RATIOMETER SYSTEM
In figure 82 the oil pressure sensor is a piezoresistive device that contains two
sensing elements. Each EEC channel supplies a n excitation signal to one sensing
element. Each element sends an oil pressure signal to its EEC channel and then
via the EDIU to AIMS for display as shown in psi.
SECOHDARY ENGINE PAGE
TERPERATURE BULBS
O I L PRESSURE TRANS
OIL P U A ~ T I T YTRANSIIITTERS CWPUTERS
CHANNEL 1
CHANNEL 8 ,
Remote temperature indicating systems are used for pneumatics, engine oil,
hydraulics, fuel etc. The example used here involves the use of resistance bulbs
as the sensor and a ratiometer type indicator.
PLUG FORMER
RECEPTACLE
\
UNION NUT
/' / BULB
CONTACTING ELEMENT
"IN /
SOCKET STRIPS
CALIBRATION OR
BALANCING COIL
The ratiometer indicator is used to give a high accuracy of indication. One of its
coils is connected directly across the supply and the other is connected in series
with the temperature bulb.
With reference to figure 84. Assume the temperature of the bulb is constant, then
the torques provided by the two coiIs are equal and opposite (coils wound to
oppose) and the system is stationary. It should be noted that the currents are not
necessarily the same. Remember the torque on a coil is proportional to current and
Pm.
Assume now that the temperature at the bulb increases, its resistance will
increase (positive temperature coefficient). The current through coil B will
decrease and its torque will decrease. Remember the current through coil A will
not change a s the coil is across the supply. There is now a n imbalance of the
torques, coil A torque is greater than coil B torque and the armature will move
clockwise carrying with it the pointer.
You should note that as coil B moves it moves closer to the magnet and into a
stronger flux area, so its torque is increasing and coil A is moving further away
from the magnet and into a weaker flux area so its torque is decreasing (T a I x 0).
At some point the torques balance and the pointer now indicates the new higher
temperature reading.
Figure 85 shows a practical indication system. Note the position of the earth for
the system, it is always close to the bulb.
blank
1rz 28V AC BUS 7.
FUELTEMP
INDICATION
LIMITING RESISTOR
Consider figure 86 showing a ratiometer instrument wiring layout. (b) shows that
the leads interconnecting the indicator and bulb have a small inherent resistance,
and this resistance changes with temperature change. Wired a s shown the lead
resistance's are both in series with the bulb and one coil of the indicator.
Therefore errors could be introduced.
This problem is overcome by connecting the earth of the dc power supply close to
the bulb as shown in figure 85c. The resistance of one of the connecting leads is
now in series with one coil while the other connecting lead resistance is in series
with the other coil in the indicator. Therefore any change in resistance of these
connecting leads effects both coils equally and a s they oppose one another there
will be no effect on the indication.
Maintenance Checks
Check your AMM for specific details but in general the follow applies.
Inspection of bulb. Visually check for damage, corrosion and security. Check
electrical connections for security signs of burning and contamination. Carry out
resistance and insulation checks.
Indicator. Check for security, legibility of markings and damage. Check that
power failure check indication moves below scale.
System Checks. This will vary from aircraft to aircraft. Some manuals state that
the temperature of oil should be measured using a thermometer and the reading
compared with the gauge. Others state disconnect the bulb and substitute a set
value of resistance and indicator should read a certain value. Some have a test
box which can simulate temperature bulb resistance's to check calibrate the
indicator.
On more modem systems the temperature bulb signals are fed to computers and
then transferred to the EICAS display (Boeing) or ECAM display (Airbus).
Figure 87 shows the oil temperature indicating system for the 777-200. The
temperature bulb has two platinum elements, the signals from these elements are
fed to the two channels in the EEC and then via the EDIU to the AIMS for display.
EPCS MAINTENAN< PAGE 212
Page
The transmitter consists of two sections combined in one unit; a flow- measuring
chamber and a data transducer section. The flow section is completely sealed
from the data transducer section.
BYPASSVALVE
SPRING /
MOVING VANE
Fig. 1 FLOW MEASURING CHAMBER
The flow measuring chamber consists of a measuring vane, which is moved by the
flow of fuel in a specially shaped convoluted flow chamber. As the vane moves
around the chamber so the gap between it and the chamber side gets wider -
allowing more fuel to pass. The moving vane is spring tensioned against the fuel
flow by a specially calibrated control spring. The vane will take up a position so
that spring tension and rate of fuel flow are in equilibrium. The chamber is
specially shaped to provide a linear vane movement per flow rate increase.
Inlet guide vanes remove any turbulence of the fuel entering the chamber. Should
the vane jam it is necessary (by regulations) to provide a bypass for the fuel. The
bypass valve is of the simple spring-loaded type adjusted to open when a
differential pressure (pressure on inlet side to pressure on outlet side) exceeds a
certain value to allow fuel to bypass.
Some transmitters also have a viscosity valve, this is a small plate cut within the
bypass valve, the position of the plate being controlled by a bi-metal spring. As
the temperature of the fuel falls this valve will start to open (at approximately
10C) to divert some of the fuel to compensate for the change in viscosity of the
fuel.
CALIBRATED
INDICATOR
MAGNETIC POINTER
COUPLING
IN OUT
FUEL 26 VAC
I
TRANSMITTER INDICATOR
The fuel entering the chamber positions the vane against the tension of the
spring. This movement of the vane has to be transmitted to the data transducer
section.
This is done by a drive magnet attached to the vane, which drives another magnet
on the data transducer section through the sealed chamber. The magnet on the
data transducer side drives the rotor of a torque transmitter synchro (TX).
The torque transmitter synchro transmits the movement to the torque receiver
(TR) in the flow rate indicator (normal torque synchro system action) to indicate
flow rate in lb/min or kg/hr.
Many systems have one instrument in the flight deck, which gives fuel flow rate as
well as total fuel consumed (fuel flow rate with respect to time). The basic system
consists of three components: the transmitter; the computer and the indicator.
AWMlNlUM ALLOY
FLUID BODY
PbSSAOEWAYS /
ROT,
TURBINE
I / 3mFT
TRI\,NING
ING
-
FUEL FLOW
CML
TO TRANSISTORIZE0
PICK-OFF BISTAsLESWITCH
COIL
The transmitter consists of two cylindrical drums, the outside drum (outer drum)
is driven by a synchronous motor at a constant speed (100 rpm). Inside the outer
drum is an inner drum called the impeller, which has fluid passages cut into it to
impart angular velocity to the fuel. The outer drum is attached to the impeller by
a linear spring. Attached to the impeller and outer drum are magnets. Below
each magnet is a pulse pick-off which is a coil.
The signals from the coils are passed to individual pulse amplifiers and then to a
bi-stable transistorised switch - all this contained within the transmitter. The
principle used in this system is that fuel passing through the impeller section will
have kinetic encrgy imparted on it as it is rotated, this kinetic energy is
proportional to its mass. It is important to measure mass as the energy released is
determined by the mass of fuel burned per unit time (Ibs per hour).
Operation
If there is no fuel flow through the transmitter then the outer drum and impeller
will rotate at the same speed with no relative angular displacement, which means
the two magnets will be passing their coils at the same time.
One of the magnets (outer drum) induces an emf in the coil which will switch on
the transistor, the other magnet (impeller)induces an emf to switch off the
transistor. A s they are rotating together then the transistor is switched on and off
simultaneously. In practice there is a slight angular difference. When fuel enters
the transmitter it first passes through straightening vanes around the motor to
remove any angular velocity the fuel may possess.
The fuel then passes into the impeller section where a constant angular velocity is
imparted to the fuel. (Remember the outer drum is driven at constant speed and
is attached to the impeller by a linear spring). This causes the impeller to lag on
the outer drum, the angular displacement being proportional to fuel flow rate.
The angular difference between the two drums means that the transistor will be
switched on by the outer drum magnet pulse and switched off by the impeller
magnet pulse when it comes round. This means the bistable switch will be
producing a series of pulses, the width of these pulses is proportional tofuelfiow
rate.
ROTATION
ROTATION
Operation
* Low fuel flow rate - small angular displacement of outer drum and impeller
- transistor switched on for short time - small pulse width.
* High fuel flow rate - large angular displacement of outer drum and impeller
- transistor switched on longer time - larger pulse width.
Thus the transmitter is producing a series of pulses which are fed to the
computer.
The flow rate section of the computer consists of a signal comparator (SC), a
modulator (MOD) and an amplifier.
SUPPLY 10 I R A N S M I I I E R
--
SYNCHRONOUSMOTOR
-
PICK-OFF SIGNALS
TRliNSMiiTER
,--------------------- FLOW R A T S
REFERENCE
WINDING
S,GN".&S
e
9
'------...-------..--
COMPUTER
FLOW RATE
SIGNALS
TiML BASE
StCiiON
INDICATOR
The indicator in the flow rate section is driven by a 2-phase servomotor. The
indicator pointer is attached to a potentiometer, which controls a signal to a time
base section. The signal from the time base section is effectively a feedback signal
to the signal comparator in the computer. The fuel flow transmitter signals are
fed to the signal comparator. If there is any difference between feedback and
transmitter signals a signal is sent to the motor (via modulator and amplifier) to
reduce the error to zero and correct the indicated fuel flow.
The fuel consumed section of the computer consists of an inhibitor, gate and
divider. The inhibitor blocks any low fuel flow signal (typically below 300 kg/hr or
less) so that n o signal reaches the indicator a t no fuel flow conditions. The
indicator is a solenoid actuated 5 drum digital counter and pulse amplifier.
A reset button is provided for resetting to zero. The transmitter signals are passed
through the inhibitor to the gate, the gate is 'opened' by the transmitter signals,
a n oscillator injects signals into the transmitter signal, the number of pulses from
the oscillator that can be put into the transmitter pulse is a measure of fuel
consumed, ie each pulse represents a quantity of fuel.
*or01
FUEL FlOW 'olc'
INDIUTMI c
w mi
ELECTRONICS MODULE
FUEL USED
SWITCH
wmn rr, rutr uyb
IIDiClTOLI
Operation
The swirl generator establishes a vortex i n the fuel flow which causes the rotor to
spin. Two permanent magnets on the rotor induce pulses in a 'start coil' and a
'stop coil'. The start pulse is induced a s the first magnet passes a coil whose axis
is perpendicular to the fuel flow direction.
The stop pulse is generated as the second magnet passes the signal blade, which
is attached to the turbine.
The deflection of the turbine increases with increasing fuel flow rates, increasing
the time between the start pulse and stop pulse. The time difference is t h u s
proportional to fuel flow rate. The start and stop pulses are transmitted to the
EICAS (a Boeing system - Engine Indicating & Crew Alerting System) for
conversion and flight deck indication of fuel flow rates.
Figure 7 shows a simplified system and figures 8 to 11 show details of both EICAS
and ECAM systems. ECAM - Electronic Centralised Aircraft Monitor - Airbus.
Study the drawings and relate the details to the text.
OW DIRECTOR
CIRCWFERENTIAL GENERATOR (POVBLE SPRING
10 RICH PRESSURE f INGERS)
COIL (STOP)
ENGINE OIL
PARAMETERS
SECONDARY ENGINE
PI\RAHETERS
ENGINE
VIBRATION
i
Fig. 8 LOWER EICAS DISPLAY
TAT + tC
U T t U-c
Transmitter Maintenance
This will involve the visual checking and inspection of electrical connections for
security, contamination, signs of burning etc. Checking the bonding and that the
unit is fitted securely the right way round in the system (though it should be
"Murphy Proofed"). Check for any signs of leaks.
Indicator Testing
This will vary from aircraft to aircraft, small aircraft may just inject various
current values into the indicator, ie each particular current value is equal to a
fuel flow reading plus or minus a tolerance.
Other aircraft may use an audio oscillator to simulate fuel flow by injecting
various frequencies, each frequency represents a fuel flow figure.
Larger aircraft may have full test facilities available on the front of the computer -
checking for shorts on the transmitter motor circuit and faults in the computer
and indicator a n d functionally checking the indicator for accuracy.
Transmitter Testing
Engine Run
Again this will vary, but in general will consist of running the engine at idle and
checking for leaks and noting the fuel flow figure. Running the engine to
maximum rpm, recording the fuel flow figure and checking that it is within limits
as laid down in the AMM. Compare fuel flow rates between engines on the same
aircraft. These should all be within the stated tolerances. Checking for leaks.
On many aircraft the barometric pressure and outside temperature will have to be
recorded, and used to convert the fuel flow figures a t idle and maximum to a final
figure taking into account these parameters. This conversion table is given in t h e
AMM. The final figure is again compared with laid down values and tolerances.
Before any maintenance is carried out, of course, the AMM must be consulted.
blank
ELECTRONIC ENGINE CONTROL
For many years the control of the jet engine h a s been by the u s e of Hydro
Mechanical Control systems (HMC)- consisting of a manually operated thrust
lever on the flight deck moving a fuel control device on the engine via push/pull
rods and/or steel cables. To reduce fuel consumption, increase the engine
operating life and reduce pilot workload, electronic engine control was introduced.
1. Supervisory Systems.
2. FADEC.
SUPERVISORY SYSTEMS
This involves fitting an electronic control system, which, within a limited degree of
authority undertakes the 'fine-tuning' of the hydro-mechanical control by an
Electronic Engine Control (EEC) unit and a torque motor. With failure of the
Electronic Control Unit the engine can continue to be operated by the
conventional HMC. We shall look at two supervisory systems, one where on a n
aircraft without EPR Ni is the command value for thrust a n d the other on an
aircraft with EPR, and this is used a s the command value for thrust.
Supervisory System 1
The Power Management Control System integrates the engine computers, sensors
and controls with the aircraft computers. The sensors and controls are to
facilitate thrust settings and protect t h e engine. The system interfaces four
different computers; the Main Engine Control (MEC),the Power Management
Control (PMC), the Thrust Management Computer (TMC) a n d t h e Digital Air Data
Computer (DADC). The term Power Management Control (PMC) is used
interchangeably with the term Electronic Engine Control (EEC).
The primary purpose of the PMC system is to reduce pilot workload by computing,
displaying and maintaining the selected engine settings a s a function of external
parameters and. selected flight modes.
Main Elements
The two main elements of the Power Management Control System are the EEC
and the MEC.
Fig. 12 POWER MANAGEMENT CONTROL SYSTEM
MEC Inputs
The core engine speed (N2) (twin spool engine) is available through the accessory
case drive of the MEC.
Power Lever Angle (PLA) is provided by a mechanical linkage from the night
compartment.
Mechanical linkages provide variable stator vane and variable bleed valve position
feedback.
The fuel control switch on the flight compartment quadrant stand controls the
fuel condition actuator motor to provide fuel on-off control at the MEC.
EEC Inputs
An electrical Ti2 sensor mounted on the f a n case provides the f a n air inlet
temperature (T12).
The control alternator is driven by the accessory gearbox to provide power for the
EEC and also provides a n N2 signal for flight compartment indication.
The engine pneumatic system air bleed condition signals are analogue inputs
from the EEC discretes card to the EEC, to determine the amount of bleed air
being extracted for aircraft use.
The DADC inputs digital signals for Mach Number (Mn),Total Air Temperature
(TAT) a n d total pressure (Pt).
The Thrust Lever Angle (TLA) is a n analogue input from a resolver in the control
stand on the power lever assembly on the flight deck.
An ON-OFF switch-light on the control stand can disable the downtrim authority
of the PMC.
Fan inlet temperature (T12) and Static Pressure (Po) are also input from dedicated
sensors to back u p the DADC inputs.
The EEC computes the N1 command value based on the TLA a n d existing
environmental conditions. The EEC also receives a n actual N1 speed signal from
the engine mounted sensor and this speed signal is compared to the computed N1
command signal.
If a difference is noted, a torque motor drive signal from the EEC will adjust the
MEC downtrim mechanism to make the actual speed agree with the computed N1
command.
This action will eliminate overshoot when adjusting the thrust levers. The MEC
senses only N2,but power is set using Nl. The EEC will adjust the downtrim as
necessary on the MEC to maintain a constant NIrating with varying conditions of
speed, altitude, temperature, bleed demand, etc allowing a 'hands-off power
control.
EEC Power
EEC De-activation
The faillfured feature, if activated, will release allowing downtrim to return to zero.
It may be necessary to adjust the power levers in the retard direction slightly to
set the desired N1 speed.
EEC Monitor
The EEC contains a volatile fault memory that will clear on engine shutdown. The
EEC monitor is an airframe microprocessor that will store PMC faults on
touchdown, to allow recall after engine shutdown.
The EEC receives inputs of pressure and temperature from three different
sources. A disagreement between two of the three sets of data will cause the EEC
to reject the discrepant data and base its computations on the remaining data.
The EEC will alert maintenance of the discrepancy through the EEC monitor
interface. If the comparison between data shows a substantial disagreement or
sensor input failure, the EEC will activate the faillfixed mode.
The DADC's provide digital inputs of Mn, Pt and TAT to the EEC. The EEC also
has independent Poc and Ti2 sensors that allow the necessary computations to be
performed should the DADC inputs be unavailable. The computations are not as
accurate, but are satisfactory to allow full functioning of the EEC.
SUPERVISORY SYSTEM - 2
This is a system similar to the above but fitted to another engine type (figure 13).
Note the similarities/differences.
Electronic Engine Control (EEC) ensures that the actual thrust level is
consistently controlled to match the exact thrust level requirement. Utilising
numerous inputs, the EEC maintains the selected rating by transmitting a trim
signal to activate a torque motor in the fuel flow governor to adjust fuel flow. It
also provides EGT and shaft speed limitingjknction to safeguard the engine during
f u l l throttle operation.
The EEC consists of two electrically separate parts; a supervisory and a limiter
section, each having its own power supply a n d its own ON/OFF/INOP alternate
action switch control.
Power
The power for EEC operation is from the dedicated generator system, however,
aircraft power is available for switching (ON/OFF) and also through a test switch
for testing the system with the engine shut down.
A switch adjacent to the EEC will activate a self-test and a two-digt LED which
displays stored fault codes.
DEDICAED EEC SUPERVISORY! Lp FUEL
GEHEMIOR LlAIiTER PRESSURE
/ SWIICH
TRANSIENT
FUELCODLED
FAN STREAM
TEMPERATURE
FUELDRAINS
TANK EJECTOR
DEDICATED
CENERliTOR lANK
FAULT CODE
WINDOW.
SUPERVISORY
The s u p e ~ s o r y
h a s BITE capability and provides validity checks on all signals
If the s u p e ~ s o r is
y now inhibited by de-selection of the flight compartment EEC
switch, the limiter unfreezes the torque motor current and continues normal
'limiter only' operation.
LIMITER SECTION
The limiter monitors EGT and N1 rpm and prevents these variables from
exceeding the stored limit values by down trimming the FFG.
The limiter is a real-time digital processor with multiple inputs and a n output to
the torque motor on the FFG that downtrims the hydro-mechanical control.
The limiter may also be used in conjunction with the optional supervisory control
and both may be combined into a single EEC unit.
Control
A n alternate action switch for each EEC limiter function is located on the pilot's
overhead panel (PS). (Alternate location P-10 quadrant). This switch also
contains an 'INOP' light. With the switch in the normal 'ON' position power from
the DGCU (Dedicated Generator Control Unit) No 1 will activate the internal power
supply i n t h e EEC and energise the circuit, which in the event of a fault will
energise the Fail Fixed Solenoid and freeze the trim motor. In the 'OFF' position a
ground is provided for the INOP light and to the EICAS to display a level C 'L/R
ENG Limiter' message.
Operation
The limiter receives inputs of N I and EGT from engine sensors and compares
them against stored maximum limit values. If a limit is exceeded the limiter
generates a trim current to the torque motor large enough to reduce the engine
operating level to the N I or EGT limit. This trim current is compared to the trim
current input to the limiter by the supervisory, if installed. The higher of the two
trim currents is sent by the EEC to t h e fuel flow governor.
If a failure is detected in the limiter, the fail ftved solenoid is activated, which
locks the torque motor in its existing position and a discrete is sent to the limiter
INOP light, a n d the EICAS computers, to indicate failure.
If the limiter is inhibited by de-selection of the flight deck limiter switch, the fail
fixed locking solenoid is de-activated and the supervisory transmits the trim
current directly to the torque motor without passing through the limiter.
Auxiliary Backup
If both supervisory and the limiter are inhibited, the trim current resets to zero
and the fuel flow regulator is under complete hydro-mechanical control.
This system, as the name implies, assumes full responsibility for everything to do
with control and protection of the engine. Transmission of throttle (thrust lever)
position is usually performed by digital electronic means and there are no
mechanical connections as in the supervisory system.
These features also offer great improvements in the auto-thrust system, reducing
throttle activity during automatic operation, thus limiting wear and reducing fuel
consumption.
There are variants of the FADEC system but the ones covered here will cover most
of the main components and parameters of a typical FADEC System.
Functions
The FADEC system is powered by the aircraft electrical supply system below 15%
N2 and is self-powered above 15% Nz. Figure 16 shows t h e inputs and outputs to
the ECU and figure 17 shows the basic layout of the system a n d its components.
CONTROL SIGNALS
ALTERNATOR
MITORING SIGNALS
STARTER AIR
VALVEISTARTER
Each FADEC unit requires inputs of total pressure, total temperature and
pressure altitude to function normally.
In addition to the ADIRU (Air Data and Inertial Reference Unit -Airbus) inputs it
receives its own independent measurements of inlet pressure, inlet total
temperature and ambient pressure from:
h
A dual element temperature probe (one per channel).
* A dedicated total pressure probe (plumbed to the FADEC unit
sensor, which is hardwired to each channel).
* Dedicated ambient pressure ports (plumbed to the FADEC unit
sensor, which is hardwired to each channel.
ADIRU data are the preferred inputs to be used, when validated by engine data,
over FADEC airdata sensors and are used whenever possible for rating
calculations.
So for failure of Air Data inputs, ie no Air Data signals to both channels, these
hardwired sensor signals would be used. Failure of Air Data input would be
indicated on the Flight Deck.
Electronic Control Unit (ECU)
This is the 'brain' of the FADEC system and consists of a dual channel digital
electronic control with cross-talk (if failure of a sensor signal to a controlling
channel it will use the signal from the standby channel) and failure detection. The
best working channel always being in control.
The ECU receives inputs from the Air Data and Inertial Reference System (ADIRS)
and operational commands from the Engine Interface Unit (EIU) also inputs from
the various dedicated engine sensors and throttle lever angle (TLA). With this
infonnation it computes the necessary fuel flow, Variable Stator Vanes (VSV)
position, Variable Bleed Valves (VBV)position, High Pressure Turbine (HPT)
clearance control, Low Pressure Turbine Clearance (LPT) clearance control and
Rotor Active Clearance Control (RACC)valve positions, and provides the necessary
current to the torque motors in the HMU.
The ECU also performs ON/OFF control of the Ignition relays, Starter Air Valve
Solenoid, the Aircraft Thrust Reverser Directional Valve and the Thrust Reverser
Pressuring Valve.
The ECU provides digital output in ARINC 429 format for display of engine
parameters on ECAM, FMS and the aircraft maintenance data system.
The ECU is powered by a three-phase alternator above 15% N2, aircraft power
being used u p to this point. The unit is a vibration isolated single unit mounted
on the fan case and is force air-cooled.
Electrical Connections
Channel A Channel B
Connector Connector Function
- (ODD) (EVEN)
Jl 12 Airciafi Power (28") &Igniter Power (1 15")
J3 14 Aiiciaff InoutiOutout & TLA
1 17
19
Jli
18
JIO
J12
Solenoids, Torque Motors, Resolvers, N2
Alternator, SAV, NI & TI2
LVDT's, RVDT's, T25, BSV position switch
J14 Engine Identification plug
113 Shared WP Metcr, Thcmocouples
Ji5 Shared Test Interface & Ground Power
Electrical Connectors
Fifteen threaded electrical connectors are located on the lower panel of the ECU.
Each h a s a unique key pattern, which accepts only the correct corresponding
cable (Murphy Proof). Connector identification numbers from J 1 to 515 are
marked on the panel.
All engine control input and command output signals are double and routed to
and from channels A and B through separate cables and connectors. Signals
which are shared or which go to only one channel a m v e through a single
connector.
Engine Identification Plug
The engine identification plug acts as an 'electronic nameplate' for the ECU. It is
bolted onto the fan case at the 4:30 o'clock location and attaches to the 514
connector. The ECU reads the following information about the engine from an
electronic memory circuit in the plug:
Engine Model
Engine Serial Number
Engine Nominal Rating
Engine Bump/Overboost Rating
Pressure Inputs
The pressure sub-system shear plate serves as the interface between the
pneumatic lines and the ECU. The three control pressures are divided into
Channel A and Channel B signals by passages inside the shear plate.
The shear plate is bolted onto the ECU chassis. A metal gasket with integral O-
rings is installed between the plate and ECU. An alignment pin on the chassis
and the gasket assures correct orientation of the assembly. During ECU removal,
only the shear plate is removed, eliminating the need to disconnect individual
pressure lines.
Short lengths of flexible cable between the rigid pressure lines allows the shear
plate to be moved out of the way during ECU change-out. Pressure relief valves on
Channels A and B protect against overpressure of the pressure sub-systems.
The ECU is air-cooled. This airflow maintains FADEC ECU internal temperatures
within maximum limits. A flushed air scoop located on the inlet outer barrel
supplies air through a duct to the ECU. The cooling air is boosted by an eductor
if necessary and is discharged in the outlet of the engine air intake cowl anti-icing
system (outer barrel of engine of intake cowl).
The air entering the ECU flows across the cooling fins of the heat sink. For
normal operation (ambient temperature less than 100F (38C)or Mach number
greater than 0.4) this cooling system is adequate.
When the above flow requirement is not achieved (corresponding to deg arnb >
100F and Mach < 0.4) a n eductor located in the cooling air discharge duct boosts
the cooling airflow.
An ECU controlled valve opens, thus supplying air from the starter duct to the
eductor.
A continuous and uninterrupted power supply is necessary for the ECU to assure
control of engine systems.
Two separate aircraft power sources are connected to the ECU. They are
used when engine speed is below 10- 15% N2, or when a control alternator
channel failure h a s occurred.
The control alternator provides two separate power sources from two
independent stators. One is hardwired to Channel A of the ECU and the
other is hardwired to Channel B of the ECU. The alternator is capable of
supplying necessary power above engine speeds of 10- 15% Nz.
The Ground Support Equipment (GSE) source is used to power the ECU on
the ground when aircraft power is not available. Supplied to the ECU
through a connector which is normally capped-off in service. An automatic
temperature switch will disconnect this circuit if ECU internal temperature
reaches 120C.
ECU Power-Up
At ECU power-up, the aircraft busses supply the necessary power for all
initialisation and self-test functions of the ECU. For ground maintenance, the
GSE source can be connected if aircraft power is not available.
E n g n e Starting
During engine start the aircraft busses will supply 28 volts dc until NZ reaches
approximately 10-15%. The ECU will automatically switch to the control
alternator a s soon a s it is able to provide the necessary power.
Alternator Failure
If the alternator power supply to one channel should fail, the ECU will switch
engine control to the opposite channel. If both channels lose alternator power
supply, the ECU will switch to the aircraft b u s source.
In both cases, a fault warning will be displayed on the ECAM i n the flight deck
Aircraft and GSE power always pass through tie Boost Converter. The dc Power
Converter changes the supply voltage into internal working voltages of 5V and
25V.
Note: With engines not running the ECU is powered for the first five minutes after
aircraft power has been applied via A/C PWR UP switch or EngineIMaster
Control Switch i n the OFF position, to allow the ECU to carry out self-test
routines.
r SUPPLIED
FOR 5 MIN FADEC
The EIU is a n interface between the aircraft and the corresponding ECU (one ECU
per engine). The following aircraft data for engine management is transmitted to
the ECU:
* Flight Control Unit (FCU)- provides ECU with Flight Control
configuration (manual or autothrust).
* Environmental Control System (ECS) - provides ECU with bleed air
demand.
* Centralised Fault Display Unit (CFDU)- deals with the ECU through
the EIU to allow the use of the Centralised Fault Display System
(CFDS) during maintenance actions. The CFDU gives access to the
ECU Non-Volatile Memory (NVM) through the EIU. Information is
displayed on CRT displays on the flight deck.
The EIU provides the aircraft electrical supplies to the ECU, 2 x 28v dc and 2 x
115v ac.
The Control Alternator provides a dedicated power source to the ECU. It is the
primary power supply to the ECU a t engine speeds of greater than 10-15%N2.
The rotor contains permanent magnets and is fitted on the accessory shaft.
( CHANNELASTATOR I
I CONTROL
ALTERNATOR
1 I ENG
FADEC GND PWR
F==-al
I CHANNEL B STATOR
CHANNEL A CHANNEL B
J15 PLUG
SUPPORT
EQUIPMENT
The forward case of the housing contains 2 electrical quick disconnect plugs for
attachment of the electrical harnesses.
This is installed on the aft side of the accessory gearbox on the far left hand pad.
It receives electrical signals from the ECU and converts these inputs through
torque motor/servo valves into engine fuel flow and hydraulic signals to various
external systems. Engine fuel is the hydraulic medium.
Thrust Control:
* Commands the engines to provide the power best suited to each flight
phase.
* Automatically provides all the associated protection required.
* Either in manual (TLA).
* Or in automatic (autothrust).
Thrust selection is achieved by means of the thrust levers when in manual mode
or the Flight Management Guidance System (FMGS) when in automatic mode.
Thrust rating limit is provided by the FADEC according to the thrust lever
position both for manual and automatic thrust control.
The thrust levers can only be moved manually. They move over a sector which is
divided into 4 operating segments.
THRUST
4
.- .
. .
. MODE SELECTIONS
-\
.- - --N'- -LIMIT
----TOIGA
- - ......-- 1
N1 LIMIT FLX TOIMAX CONT
1
Y
2 8 m %
X
<
I S
2 z
- - .-.
... IDLE
ROTTLELEVER I 0 0
ANGLE
When in automatic mode, the computed NI also defines the upper limit, which
can be achieved by the Autothrust System (ATS) (independently of ATS target N1).
The engines are in the manual mode provided the Autothrust (A/THR) function is:
* Not engaged or
* Engaged and not active (thrust lever not in the ATS operating
range).
Thrust modulation is performed by the pilot moving the throttle lever from IDLE
to TO/GA position. Each position of the throttle lever within these limits
corresponds to a Ni .
Autothrust Function
The source of this parameter can be the Flight Control Unit (FCU),mounted on
the glareshield, the ECU (Engine Control Unit) or the FMGC itself. In this
purpose, the FMGCs (A/THR 1 and A/THR 2 functions) calculate a thrust target
sent to the FCU.
The FCU chooses, according to AP/FD engagement status, the FMGC used a s a
unique source for the 2 engines.
The thrust target is sent through the Engine Interface Units to the Engine Control
Units, which control the engines according to this thrust target.
The FMGCs get useful information for the A/THR functions from various sensors
of the aircraft.
Engagement
REFERENCE 4
1 PRRQWTER
With reference to figure 25, the Flight Management Guidance Computer (FMGC)
provides automatic computation of the thrust level to be set, in order to achieve
the desired aircraft flight path. This once again, in the ECU is computed with
throttle lever angle and existing environmental conditions to produce a command
signal which is compared to actual N I and produces a difference signal to modify
fuel flow to provide the required thrust level.
Flight Use
During a normal flight, the use of the thrust levers is straight forward. Let's
suppose that the aircraft is on ground before take-off. A/THR is not engaged; the
engines are controlled by the thrust levers.
Fig. 25 AUTOTHRUST MODE
For take-off, the pilot p u t s the thrust levers on to the TO/GA gate. This engages
A/THR (not active).
Note: To make a flexible take-off, the pilot would have to enter the flexible take-off
temperature on a Multi-purpose Control & Display Unit (MCDU) and put
the thrust levers on to the FLX/MCT gate.
During automatic landing, before touch down, a n audio message, 'IDLE', indicates
to the pilot that'he/she h a s to put the throttles on to 0 gate. When this is done
A/THR disengages. Then, on the ground, the pilot will put the thrust levers in the
reverse position.
Engine Starting
The ECU is able to control starting (manual and automatic), cranking and ignition
using the aircraft control Engine Interface Unit (EIU).For this purpose each
channel of the ECU is able to command the opening and closing of the Starter Air
Valve (SAV),the opening of the Fuel Metering Valve (FMV)and the energising of
the igniters. Figure 26 shows the Engine Starting Functional Diagram.
The ECU receives start information from the EIU via a n ARINC 429 bus, which
provides the following information:
I
w N N Z I S ~ X I Z
0 mEFMH:SsEMCOHTROCS
a Born i w i m AND
DPEHM M:lHE RN 6 WSOV
EHGN*SSWFRSWSTTOW (HP SHUT-OFF VALVE)
Autostart
In the ground automatic start, engine-starting control of the igniters, fuel and
starter air valve are under the full authority of the FADEC. The ECU is entirely
responsible for the engine starting sequence. It provides protection of the EGT
limit, starter engagement time limit and any abnormal start functioning. In the
air the ECU initiates the automatic sequence to command the Starter Air Valve
(opening and closing), both igniters, opening of the Fuel Metering Valve and HP
Shut Off Valve (HPSOV). Figure 28 shows the ground automatic start sequence.
-
DlCyUMXSBSW
I
NTLU-TILW
OFTHECOU(RTrovrwu
ENO/UISTWCRSW ~ ~ 7 * A T P i s s w
c% OFF
0
0
WOMS NOT RUNNING
EcvHOTPOIWIU)(EYCEPTaYUNQ
THE FIRST 5 MINUTES LITW AIC POWER
o ECU C Z X l M E S mm T K :
S T M SEWENCE
0 OHCE IDLE IS RE*MW. Klf
SWfG+3lUEWQINERUMHGUME
The FADEC:
The FADEC System controls the engine thrust rating during reverser operation.
Engine power is set automatically by the FADEC to the level required for correct
deploy and stow operations in all ambient conditions.
Actuation Logic
The thrust reverser system is controlled independently for each engine by the
associated FADEC.
. -,
1,- ECU CHANNEL A
ECU CHANNEL B
&\i--+.j
Fig. 29 REVERSE THRUST
rrm
HYI
"rmYl
as
HCU
THRUST
"LLVES
Deployment requires both ECU channels to be operating, both TLA reverse signals
for each engine and both ground/configuration signals operating.
The FADEC provides the necessary engine parameters for flightdeck display
through the ARINC 429 buses output onto the upper and lower ECAM (Electronic
Centralised Aircraft Monitor) displays. These displays are central between the two
pilots on the main instrument panels.
CTR TX F E W
I
SEAT BELTS
10 SUOXLHC
b
-
Fig. 3 1 LP ROTOR SPEED INDICATION
F Max Permissible N I (Red Strip) - If 101.4% is exceeded, a red mark
appears and remains a t the maximum value achieved. It will
disappear after a new take-off or after maintenance action through
MCDU.
TO, GA, FLX, CL, MCT mode selected by the thrust lever is displayed in
green. If FLX limit is selected, the flexible take-off temperature selected
through the MCDU's is displayed in blue.
3. N 1 Rating Limit
1. Actual EGT, normally green. Amber when 870C iEGT < 906C. Red
when EGT z 906" C.
(, 51s
Indication is green.
* Advisory if oil pressure < 16 psi (pressure decreasing) or 20 psi
(pressure increasing).
* Advisory if oil pressure > 90 psi (pressure increasing) or 85 psi
(pressure decreasing).
Becomes red associated with ECAM warning if oil pressure .: 13 psi.
Indication is green.
* Advisory if oil temperature z 160" C (temperature increasing) or > 155"
C (temperature decreasing).
Becomes amber associated with ECAM warning if oil temperature > 175" C.
Indication appears amber associated with ECAM caution when the pressure
loss across the main scavenge oil filter is excessive.
Indication appears amber associated with ECAM caution when the pressure
loss across t h e fuel filter is excessive.
6. IGN Indication
@ i%05/.C +- 90
AFTER STARTCONFIGURATION
START
CONFIGURATION
Fuel used is displayed in green from eng start to electrical power supply
cut-off.
-
Indication is meen.
Advisory below 4 qt (qty decreasing) or 6 qt (quantity increasing).
( l q t = 1.1361)
Indication is green
Advisory a t (TBD).
FADEC System Faults Diagnostics
This is achieved by intensive BITE allowing efficient fault detection. The results
are contained in status and maintenance words to ARINC 429 specification and
stored in a n NVM (Non Volatile Memory) and when requested available on the
aircraft Centralised Maintenance Display Unit.
Ground tests of electrical and electronic parts is possible from the flight deck with
engines not running through the Centralised Fault Display System.
Other Systems
Figure 34 shows the layout of another FADEC system using a Fuel Metering Unit
(FMU)instead of a Hydro-mechanical Unit (HMU).
The system consists of dual channel EEC with FMU, dedicated alternator (Nz),
actuation systems for stator vanes, engine bleeds, Active Clearance Control (AAC),
1 0 t h stage cooling air, engine and Integrated Drive Generator (IDG) heat
management control and sensors.
The signal is then amplified, integrated and passed to a rectifier and then to a
micro-ammeter calibrated in relative amplitude, ie a measurement of
displacement. On some indicators the display may be in inches/second. Should
the vibration exceed a set level a warning light will come on. A test switch on the
indicator, will (a) continuity test the sensor coil and (b)inject a test signal to the
indicator, which gives a standard reading on the indicator.
Note that some engines with dual compressors, two filters may be used. There is
normally a selector switch to select either high or low frequency filters in order to
separate the vibration indications caused by the HP compressor/
turbine assembly from those caused by the LP compressor/turbine assembly.
Accelerometer System
The accelerometers used in this system are usually of the piezoelectric type. A
piece of piezoelectric material is either bonded or mechanically attached to a
mass. A piezoelectric material is one which generates an electrical charge when
subjected to mechanical strain (change in length which is extremely small). If the
crystal and mass are subjected to vibration, the inertial force of the mass acting
on the crystal produces strain and an electrical charge proportional to the applied
acceleration is produced. This may be single or double integrated to give a signal
proportional to velocity or displacement respectively. Accelerometers are rated in
pC/g (pico-coulomb/g).
In accelerometer systems the filter normally used is a band passfilter, this only
permits a selected band of frequencies to be passed to the indicator. It filters out
the high frequency signals produced by blade passage and the low frequency
signals not related to rotor imbalance.
The system shown in figure 36 is typical and based on the Boeing aircraft.
The system uses two sensors, one mounted on the fan for N1 rotor vibration and
the other mounted on the compressor to sense NI and Nz rotor vibration. Each
sensor is of the accelerometer type and as vibration occurs the electrical charge
produced is collected by the metallic collectors and transmitted to the vibration
monitor unit.
Each unit receives inputs from all vibration sensors and N I and Nz speed sensors
from each engine and sends both broadband (average)and tracking filtered data
to the EICAS computers via a databus.
Tracking filters sense the amplitude of vibration that matches the rotor speed.
The filters 'track' the rotor speed and filter out any unmatched frequencies that
may occur from outside sources.
f l U SEUSOR
S l R I L A R IUPUI
Q
FORWARDNi SENSOR
e PtaoELEcTRlc METnLUc
'
L -,' VIBRI\IION SENSOR DtTAiLS
AFT SENSOR
The multiplexer sends broadband and tracking filter signals to the EICAS
computer and also samples each tracking filter. Software then compares the
sensor signals and determines which tracked signal i s to be input to the EICAS
computer as a function of 'worst case' to be displayed. Therefore the engine may
show a broadband vibration, NIor N2.
If one of the sensors fails, the indication reverts to a broadband (BB) indication. If
vibration exceeds 2.5 units for more than 8 seconds a n ALERT warning will
appear.
A BITE on the vibration monitor unit tests the system a n d produces a fault code
to identify the problem.
Fig. 39 LOWER EICAS DISPLAY UNIT
MANIFOLD PRESSURE
The manifold pressure gauge is a n absolute pressure gauge and therefore reads
atmospheric pressure when the engine is not running. The gauge consists of two
bellows, one connected to the intake manifold of the engine and the other sealed,
evacuated and fitted internally with a controlling spring.
/
SHAFT PNOT
EPR gives a good indication of the real power (thrust) from a pure jet engine. On
some jet engines only rpm is available. If a n engine is driving a propeller or a
rotor (as in a helicopter) then the torque of the output shaft best indicates the real
power (Shaft Horse Power - SHP) output of the engine. Fitted to engines driving
propellers and helicopter rotor systems.
Torque is basically a twisting action. ALL shafts twist to some degree when
subjected to torque. It is calculated as the perpendicular force times the distance
to the centre of the fulcrum or shaft (F x d). Torque will only be produced if the
shaft being driven is resisted by something - with aircraft this is a propeller or
rotor assembly. Torque is independent of shaft rpm and is measured in ft lb in
the imperial system and Newton metres (Nm)in the SI system.
Typical methods of transducing torque are:
* Strain gauges. These are small devices, which are bonded to the
shaft in question, and when mechanical strain is applied the resulting
change in resistance (due to change in length of the silicon resistor) is
a measure of the strain applied. The strain gauges are usually
connected in a bridge circuit, which is temperature compensated, to
provide an accurate electrical output of the strain measured. Slip
rings provide for power supplies and pick-off readings.
* Hydraulic system. This is fitted, usually within a gearbox
arrangement, and is driven by the engine output shaft. The gears
incorporate two or more helically c u t gear wheels which, when torque
is applied, move in an axial direction. This axial movement causes a
pressure signal to be generated using a piston/s and cylinder/s
arrangement.
Some engines use a single set of gear wheels while others use a
planet gear arrangement.
* Phase displacement system. This measures the displacement
between the torqued shaft and a false or un-torqued shaft. Fitted on
the power output shaft between the engine and the propeller/ rotor
drive system. The displacement can be measured using magnetic
pick-offs or light.
Hydraulic System
With reference to figure 42. This system u s e s a single pair of meshing helical
gears with the power being applied through the input gear and the output gear
driving a propeller or rotorshaft.
When a torque is put through the helical gears so the inclined planes of the teeth
mean that there is a tendency for the gears to move in a n axial direction, while
they are rotating. The output shaft is constrained in bearings so it cannot move
(it rotates of course), but the helical driving gear carrying the torque meter piston
h a s axial freedom to move.
As the torque is increased so the helical driving gears will move axially to the left
(in figure 42). This movement moves the torque meter piston to the left increasing
hydraulic pressure to the pressure transducer.
The torque meter piston is prevented from rotating by the use of a guide pin
A spur gear pump supplies oil a t 150 psi (1GPa). The bleed hole allows a small
continuous flow of oil through the system to prevent 'oil stagnation'.
Fig. 42 HYDRAULIC TORQUE MEASURING SYSTEM
The electrical signal from the transducer may be dc to a moving coil gauge in the
flight deck or it could be a ratiometer system.
The next diagram shows the principle of a torque indicating system using
synchros.
MCK PIN10
TOROUEMETER
PRESSURE
2 PHASE
MOTOR
The transmitter consists of, the bourdon tube, gearing and CX (Control
Transmitter). This is mounted directly on the engine and is connected to the
pressure source. The indicator consists of a CT (Control Transformer), amplifier
and servomotor.
Figure 44 shows a practical system using synchros on a twin engined Bell 412
helicopter. Study the drawing and check you understand how the system works.
Figure 45 shows an arrangement using planet gears. When torque is applied the
gears move forward onto a pressure plate, which in turn moves a piston in a
cylinder to produce hydraulic pressure.
This usually involves a load shaft mounted within a hollow 'false' shaft. The load
shaft takes all the torque being produced by the engine and the fdse shaft is
unloaded.
When torque is applied the load shaft will twist and the false shaft will not. The
amount of twist (angular displacement) can be measured.
With reference to figure 46. The torque meter unit consists of two toothed wheels,
one mounted on the propeller shaft and the other on the forward end of a false
shaft, the rear end of which is welded to the outer surface of the propeller shaft.
As each tooth on the wheels passes the pick-up stator, so it will increase the flux
density of the permanent magnet, as each gap (between the teeth) passes, so the
flux density wiIl be reduced. This varying flux field will induce an alternating
current into the coil the frequency of which is dependent only on the speed of
rotation of the toothed wheel.
Signals from both wheels will be sent to the electronic unit where conditioning of
the signal will result in the sine waves being transformed to square waves.
The two waves are compared and the difference sent a s a dc signal to a flight deck
gauge indicating torque in Nm.
With no torque in the system (but with the shafts rotating) the load shaft is not
twisted and the teeth on its wheel pass the transducer coils a t the same time a s
the teeth on the false shaft. The resulting signals are in-phase and zero torque is
indicated.
When torque is applied (by increasing the pitch of the VP propeller or increasing
the collective pitch of the main rotor blades of a helicopter) the load shaft will
twist. Because the false shaft is only connected at one end it will not experience
any twist.
Now the two wheels will be out of phase with each other - with the teeth of one
being slightly in front of the teeth of the other. Thus the pick-up stator will send
two out of phase signals and the amount they are o u t of phase will be directly
proportional to the amount of torque being p u t through the load shaft.
Another way of organising the phase displacement method i s to have a drive shaft
and two false shafts (figure 48).
RESISTANCE MODULE
-TORQUE INDICATOR
FALSE SHAFT
VIEW ON ARROW
Each false shaft is attached to the respective end of the drive shaft but not
attached at the 'wheel' end. False shaft 1 carries a notched wheel a n d false shaft
2 carries a spigot wheel.
When torque is put through the power shaft it will twist and cause the notched
wheel and spigot wheel to move circumferentially relative to each other.
As the assembly rotates so the notches a n d spigots in the two wheels pass a
transducer coil. As they are made of a ferro-magnetic material this will produce
a n alternating flux field across the transducer coil and a n output which will
indicate the relative positions of notches and spigots.
COIL'
POWER
* SIGNAL LENGTH
- 53 -
Figure 49 shows the relative position of spigot and notch at a low torque setting
with the output signal from the transducer showing equal lengths for G1 and G2
gaps. Figure 50 shows the position at a higher torque setting with unequal G1
and G2 gaps.
On some aircraft the above system is used with a light emitting transducer. The
two false shafts are not too unlike those described but are designed in such a way
a s to allow light to shine through the notched and spigot wheels.
The light source is on one side of the wheels. The light pulses are picked up by a
light sensitive transducer on the other side of the wheels and converted to
electrical pulses to be converted yet again to an electrical signal suitable for a
cockpit instrument.
PROPELLER SPEED
Typically the speed indicating system consists of a speed sensor (Np)and an rpm
indicator.
The speed sensor is of the magnetic pick-up (pulse probe) type and is mounted on
the engine reduction gearbox.
The signal from the sensor is fed to the indicator, which has a moving pointer
against a fxed dial and also has a digtal display. In the example shown the
sensor signal is 0-5volts peak-to-peak equivalent to 0-1200rpm propeller speed.
Circuits in each indicator compute the ac signal from its sensor and provide an
equivalent indication of propeller rpm (Np)by a moving pointer against a fixed dial
and a n equivalent digital display.
The indicator dial is marked PROP RPM x 100 and the scale is graduated in major
graduations of 10 RPM from 0 to 1500 RPM, with minor graduations in
increments of 5 RPM. Range markings are yellow arc 500 to 780 RPM, a green
arc 780 to 1200 RPM and a red radial at 1200 RPM.
NP PROBE HYD PUMP GEAR
PROPELLER
SHAFT
AC
TORQUE
.- SENSOR
BULL GEAR
BRAKE
TORQUE SHAFT
TORQUE SENSOR FIRST STAGE HELICAL GEAR
PRESS-T(;-TEST
The digital display is a four digit, liquid crystal display (LCD). A press-to-test
pushbutton can be used to verify the correct operation of the indicator, when
pressed the indicator aligns with a blue dot a t 1050 rpm with a n equivalent digital
display, when released both indications show zero.
In the event of indicator electrical power failure, the indicator moves off scale
below zero and the digital display is blanked.
PROPELLER SYNCHRONISING
With propeller driven aircraft (either piston or jet engined) vibration is produced
by the propellers. This has an adverse effect on structures, components, crew
fatigue, passenger comfort etc. On multi-engined aircraft the problem is
compounded by the interaction of all the propeller vibrations with each other.
This adverse interaction can be reduced (and hence the vibration and noise can
be reduced) by synchronising/synchrophasingthe propellers.
Synchronising is adjusting the enginels so that all engines run at the same rprn -
though the propellers might be at any angle relative to each other at any one point
in time (phase angle).
Synchrophasing is ensuring that all propellers run at the same rprn (as in
synchronising) but at a slight relative difference in phase angle -which is fured
(see later notes).
I I \ / I I
I
SAME ANGLE -VIBRATION DIFFERENT ANGLES - LESS VIBRATION
Fig. 53 SYNCHROPHASING
Synchronisation Systems
The propeller synchronisation system is used to set all governors at exactly the
saiie rpm, thereby reducing noise and vibration. A synchronisation system may
be used with mechanical or electrical governors.
The synchronisation system is normally used for all flight operations except take-
off and landing. A master engine is used to establish the rpm to which all other
engines (slave engines) will adjust.
This is not very practical because the individual instruments can have different
permissible indication errors and when made to read the same operating speeds,
the engines may in fact be running at speeds differing by an amount equal to the
indication errors. In addition, the synchronising of engines by a direct
comparison of rpm indicator readings is made more difficult by the sensitivity of
the instruments causing the pilot to overshoot or undershoot an on-speed
condition by having to 'chase the pointers'.
In order to allow manual adjustment of rpm a n additional instrument known a s
synchroscope is used. It provides a qualitative indication of the dqferences in
speeds between two or more engines and by using the technique of setting up the
required on-speed conditions on a selected master engine, the instrument also
provides a clear and unmistakable indication of whether a slave engine is running
faster or slower than the master.
Figure 54 shows the instruments for a twin-engined (left hand) and a four-engined
(right hand) aircraft. Note that in each case there is one less pointer than there
are engines. The master engine does not have a pointer - only the slaves.
When a slave engine is running faster or slower than the master, its pointer will
rotate in the appropriate direction - the greater the speed the greater the
difference between slave and master engine rpms.
Fig. 54 SYNCHROSCOPES
The pilot will nudge the appropriate throttle lever forward or back to get the
pointer to slow and eventually stop.
The operation is based on the principle of the induction motor, which, in this
case, consists of a three-phase star-wound stator and a three-phase star-wound
rotor pivoted within the stator. The stator phases are connected to the tacho-
generator of the slave engine while the rotor phases are connected to the master
engine tacho-generator via slip rings and brushes. A disc at the end of the rotor
shaft provides for balancing of the rotor.
DiRECTiON OF ROTOR
DIRECTION OF ROTOR ROTATiON DUE TO
ROTATION DUE TO STATOR TORQUE
REACTIVE TOROUE
RESULTUITOFSTATOR
FlEW UGGING
RESUCIANT OF
STATOR F l E W
RESULTPNl OF LEADING RESULTANT OF
ROTOR FIELD ROTOR FIELD
This torque causes the rotor to turn in a direction opposite to that of its field so
that it is forced to continuously try to realign itself with the lagging stator field.
The continuous rotation of the rotor drives the pointer round to indicate that the
slave engine is running SLOW and that an INCREASE of speed is required to
bring it into synchronisation with the master engine.
If the slave engine should run faster than the master then the synchroscope
stator field would lead the rotor field, reaching maximum strength at, say, point
b-b (figure 55). The stator field would then produce the greater torque, which
would drive the rotor to realign itself with the leading stator field, the pointer
indicating that the slave engine is running FAST and that a DECREASE of speed
is required for synchronisation.
BRUSH BLOCK
ASSEUB LY
/
__ B R M BLOCK
ELECTRICAL
CONNECT08
CWTROLLED
- 59 -
Synchrophasing
The propeller synchrophasing control circuits provide for automatic and phase
angle synchronising for the propeller system.
The synchrophasing mode in the example shown is manually selectable and must
remain switched off during take-off and landing or when operating the propeller
outside the cruise range.
ENGINE HARNESS
REAR Dt9U)NHECT
The pulse generators are aligned axially with sensor actuators located on the rear
face of the propeller bulkhead and slip ring assembly of each engine.
With SYNCHROPHASE selected (advisory light 'ON') the signals from the pulse
generators are processed by the synchrophase control box. Circuits using the
signal from No 1 propeller pulse generator a s the master signal relays a correction
signal a s required to the torque motor of engine No 2 PCU. The torque motor
operates through the PCU to synchronise the propellers.