Systems of Commercial Turbofan Engines

An Introduction to Systems Functions

Bearbeitet von
Andreas Linke-Diesinger

1. Auflage 2008. Buch. xv, 234 S. Hardcover

ISBN 978 3 540 73618 9
Format (B x L): 15,5 x 23,5 cm
Gewicht: 1170 g

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Table of Contents

1 Introduction ................................................................................................ 1
1.1 Engine Systems in General ................................................................. 1
1.1.1 Grouping of Engine Systems ....................................................... 2
1.1.2 Demands on Engine Systems ...................................................... 5
1.2 Digital Aircraft Systems...................................................................... 8
1.2.1 General .......................................................................................... 8
1.2.2 Federated Avionics Architecture............................................... 11
1.2.3 Integrated Modular Avionics..................................................... 11
1.3 Aircraft-Engine Interface .................................................................. 13
1.3.1 Structural Interface ..................................................................... 13
1.3.2 System Interfaces ....................................................................... 14
1.4 Thermal Management........................................................................ 14
1.4.1 Thermal Management for Engine Parts .................................... 14
1.4.2 Thermal Management for Fuel and Oil .................................... 15
1.5 Sample Engines.................................................................................. 15
1.6 Definitions and Terms ....................................................................... 17
1.6.1 Gas Path Stations........................................................................ 17
1.6.2 Pressure Ratios ........................................................................... 18
1.6.3 Shaft Speed Designations .......................................................... 19
1.6.4 Corrected Parameters ................................................................. 19
1.6.5 Location Designations on Cases................................................ 20

2 Engine Air Systems .................................................................................. 23

2.1 Internal Air Systems .......................................................................... 23
2.1.1 Component Cooling and Sealing............................................... 23
2.1.2 Pressure Balancing ..................................................................... 27
2.1.3 Bearing Compartment Pressurization ....................................... 28
2.2 External Air Systems ......................................................................... 29
2.2.1 Cooling and Ventilation Systems .............................................. 29
2.2.2 Active Clearance Control Systems............................................ 31
2.2.3 Compressor Control Systems .................................................... 38

3 Engine Lubrication System .................................................................... 49

3.1 General ............................................................................................... 49
VIII Table of Contents

3.1.1 Properties of Engine Oil ............................................................ 49

3.1.2 System Design and Components............................................... 51
3.2 Lubricated Areas................................................................................ 53
3.3 System Components .......................................................................... 55
3.3.1 Oil Tanks..................................................................................... 55
3.3.2 Pumps and Filters ....................................................................... 56
3.3.3 Oil Cooling ................................................................................. 58
3.3.4 Vent System Components.......................................................... 59
3.4 System Indications and Monitoring.................................................. 60
3.4.1 Indication of Operating Data ..................................................... 60
3.4.2 Indication System Sensors ......................................................... 61
3.4.3 Data Processing, System Monitoring........................................ 62
3.4.4 Debris Monitoring ...................................................................... 62

4 Engine Fuel Distribution System ........................................................... 67

4.1 General ............................................................................................... 67
4.1.1 Properties of Fuel ....................................................................... 67
4.1.2 Fuel Supply of the Engine ......................................................... 69
4.2 Engine-Mounted Fuel Distribution System ..................................... 70
4.2.1 System Design and Components............................................... 70
4.2.2 Operation .................................................................................... 72
4.3 Thermal Management for Fuel and Oil............................................ 77
4.3.1 Oil Coolers and Fuel Temperature ............................................ 77
4.3.2 The Oil Cooling System of the CFM56-7B.............................. 78
4.3.3 The Oil Cooling System of the CFM56-5A, -5B and -5C....... 78
4.3.4 The Oil Cooling System of the PW4000 .................................. 80
4.3.5 The Oil Cooling System of the V2500-A5 ............................... 81

5 Engine and Fuel Control System ........................................................... 85

5.1 Main Tasks of the System ................................................................. 85
5.2 Speed and Thrust Control.................................................................. 85
5.2.1 Shaft Speed Control ................................................................... 86
5.2.2 Thrust Control ............................................................................ 87
5.2.3 Engine Thrust Ratings................................................................ 90
5.3 Hydromechanical Control Systems .................................................. 93
5.3.1 Engine Control System of the CFM56-3 .................................. 93
5.3.2 Control System of the CF6-80C2 (PMC Version) ................... 96
5.4 FADEC System.................................................................................. 98
5.4.1 System Design ............................................................................ 98
5.4.2 The EEC.................................................................................... 100
5.4.3 The Sensors............................................................................... 108
5.4.4 Aircraft / Engine Interface ....................................................... 109
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5.4.5 FADEC Systems of Selected Engines .................................... 111

5.4.6 Future Trends in FADEC System Designs............................. 119

6 The Aircrew/Engine Interface.............................................................. 121

6.1 Engine Indications ........................................................................... 121
6.1.1 Indicated Engine Parameters ................................................... 121
6.1.2 Engine Indications on an Electronic Instrument System ....... 125
6.1.3 Engine Indications on a Classical Instrument System ........... 132
6.2 Engine Controls ............................................................................... 135
6.2.1 HP Fuel Shut-Off Control System .......................................... 136
6.2.2 Mechanical Thrust Lever Systems .......................................... 139
6.2.3 Electrical Thrust Lever Systems.............................................. 141
6.2.4 Control Switches ...................................................................... 144
6.2.5 Thrust Control during Automatic Flight ................................. 145

7 Starting and Ignition.............................................................................. 151

7.1 The Starting System......................................................................... 151
7.1.1 General ...................................................................................... 151
7.1.2 Starting System Components................................................... 152
7.2 The Ignition System......................................................................... 156
7.2.1 General ...................................................................................... 156
7.2.2 Ignition System Components................................................... 156
7.3 Cockpit Controls and Indications ................................................... 160
7.3.1 Starting System and Ignition System of the CFM56-3 .......... 160
7.3.2 Start System and Ignition System of the CFM56-7B............. 162
7.3.3 Start System and Ignition System of the V2500-A5 .............. 164

8 Thrust Reverser Systems ...................................................................... 167

8.1 Operation of Thrust Reversers ........................................................ 167
8.1.1 Basic Principle.......................................................................... 167
8.1.2 Reverser Operation................................................................... 168
8.2 Types of Thrust Reversers .............................................................. 168
8.2.1 Airflow Deflection Systems .................................................... 169
8.2.2 Actuation Systems .................................................................... 171
8.2.3 Reverser Control Systems........................................................ 172
8.3 Reverser Structure ........................................................................... 173
8.3.1 Fixed Structure ......................................................................... 173
8.3.2 Movable Structure and Actuation System Components ........ 174
8.4 Reverser Control System................................................................. 175
8.4.1 Control System of the B737-600............................................. 175
8.4.2 Control System of the A320 .................................................... 177
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9 Engine Anti-Ice System ......................................................................... 179

9.1 Ice Build-Up on Engine Parts ......................................................... 179
9.2 Air Inlet Anti-Ice System ................................................................ 179
9.2.1 General ...................................................................................... 179
9.2.2 System Components of a Pneumatic Anti-Ice System .......... 180
9.3 Spinner Anti-Ice............................................................................... 181

10 Power Plant ........................................................................................... 185

10.1 Nacelle............................................................................................ 185
10.2 Bare Engine.................................................................................... 186
10.3 Power Plant Build-Up ................................................................... 186
10.3.1 Engine Mounts ....................................................................... 188
10.3.2 Inlet Anti Ice System ............................................................. 190
10.3.3 Electrical Power Generation.................................................. 190
10.3.4 Pneumatic System .................................................................. 191
10.3.5 Hydraulic System ................................................................... 193
10.3.6 Fuel Supply System ............................................................... 194
10.3.7 Fire Detection and Extinguishing System ............................ 194
10.3.8 Mechanical Engine Controls ................................................. 197
10.3.9 Sensors and Harnesses ........................................................... 197
10.3.10 Engine Fluid Drains ............................................................. 197

Appendix A Data Transfer in Digital Aircraft Systems...................... 199

A.1 Serial Interfaces .............................................................................. 199
A.2 Data Buses....................................................................................... 201
A.2.1 ARINC 429 .............................................................................. 201
A.2.2 ARINC 629 .............................................................................. 202
A.2.3 AFDX....................................................................................... 204

Appendix B Servo Valve Control for Actuator Positioning ............... 207

B.1 General............................................................................................. 207
B.2 Servo Valves with Spill Valves ..................................................... 207
B.3 Servo Valves with Fuel Jet Nozzle ................................................ 209
B.4 Servo Valves with Pilot Valves ..................................................... 210
B.5 Fail-Safe Actuator Positioning....................................................... 211

Appendix C Unsuccessful Engine Starts................................................ 213

C.1 Types of unsuccessful Engine Starts ............................................. 213
C.1.2 The Hot Start............................................................................ 213
C.1.3 The Wet Start ........................................................................... 215
C.1.4 The Hung Start......................................................................... 216
C.1.5 The Start Stall .......................................................................... 217
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C.2 Further Abnormal Start Conditions detectable by

FADEC Systems .................................................................................... 218

Glossary ...................................................................................................... 219

Bibliography............................................................................................... 227

Index ............................................................................................................ 229