FADEC

FADEC
• What is FADEC?
• Digital Electronic Controls
• Design Requirements : Modern Engine
Control System
• Why is FADEC Preferred?
• A Backgrounder
• Location of FADEC
• Electronic Aspects of FADEC
• How does FADEC work?
• FADEC : Functions
• FADEC : Essential Features
• FADEC : Infrastructure (Simplified)
• Schematic Diagram
• Advantages & Limitations
 WHAT IS FADEC?

FADEC: (Full Authority Digital Engine Control System)

- a digital electronic control system
- able to autonomously control the engine
- throughout its whole operating range
- in both normal and fault conditions
 WHAT IS FADEC?

FADEC: (Full Authority Digital Engine Control System)

- has a self-monitoring, self-operating,

redundant & fail-safe setup
- comprises of a digital computer and the
other accessories (that control all the aspects
of aircraft engine performance)
 WHAT IS FADEC?

FADEC: (Full Authority Digital Engine Control System)

- key system of gas turbine engines

- provides optimum engine efficiency for a
given flight condition
- also controls engine starting and
restarting.
 WHAT IS FADEC?

FADEC: (Full Authority Digital Engine Control System)

- lowers the work-load of pilots,

- reduces the occurrence of pilot errors,

- provides for efficient engine operation.

 WHAT IS FADEC?

FADEC: (Full Authority Digital Engine Control System)

allows the manufacturer to

-program engine limitations and

-receive engine health and maintenance

reports.
 WHAT IS FADEC?

- no form of manual override available

- places full authority to the control of
operating parameters of the engine in
the hands of the computer.
- if a total FADEC failure occurs, the
engine fails.
 WHAT IS FADEC?

Note: If the engine is controlled digitally

and electronically but allows for manual
override, it is considered solely an Electronic
Engine Control (EEC) or Electronic Control
Unit (ECU).
An EEC, though a component of a
FADEC, is not by itself FADEC. When
standing alone, the EEC makes all of the
decisions until the pilot wishes to intervene.
 DIGITAL ELECTRONIC CONTROL

The benefits of digital electronic control of

mechanical systems are evident in greater
precision and an ability to measure or predict
performance degradation and incipient
failure.

Typical examples of this are digital

implementations of flight control or fly-by-wire
(FBW) and digital engine control, or Full-
Authority Digital Engine Control (FADEC).
 DIGITAL ELECTRONIC CONTROL

Integrated Flight and Propulsion Control (IFPC)

allows closer integration of the aircraft flight
control and engine control systems.

Flight control systems are virtually all fly-by-

wire (FBW) in the modern fighter aircraft of
today; the benefits being weight reduction and
improved handling characteristics.
DESIGN REQUIREMENTS OF MODERN
ENGINE CONTROL SYSTEM
• Speed / Accuracy / Ease of Control
(Least Aircrew Workloads)

• Wide Operational Range

• Reliability & Operational Safety

• Low Operating & Maintenance Costs

• Should Not Add Weight

• Fuel Efficiency

• Dependable Starts
 WHY IS FADEC PREFERRED?

New engines are adopting FADEC for

-the benefits offered by digital control,

-improved reliability and performance,

-weight-reduction and

-other improvements in system

integration and data flow.
 A BACKGROUNDER
The FADEC systems were first used in the
automotive Industry where it is well
proven.

Now-a-days airlines and the militaries all

over the world incorporate it on turbine
powered aircraft.

FADECs are made for piston engine and jet

engines both but they differ in the way of
controlling the engine .
 A BACKGROUNDER

Advanced, intelligent & robust propulsion

controls are critical for improving the safety
and maintainability of future propulsion
systems.

Propulsion system reliability is considered

to be critical for aircraft survival. Hence,
FADEC systems came into being.
 A BACKGROUNDER

FADEC is now common on many

engines.

Semiconductor and equipment cooling

technology has advanced so that
control units can now be mounted on
the engine and still provide highly
reliable operation for long periods.
 A BACKGROUNDER

Developing and implementing modern

intelligent engine systems requires the
introduction of numerous sensors, actuators
and processors to provide the advanced
functionality.
 A BACKGROUNDER

The application of artificial

intelligence and knowledge-based
system for both software and
hardware provides the foundation
for building the intelligent control
system of the future.
 A BACKGROUNDER

With time, control systems became more

sophisticated with the introduction of
additional engine condition sensors and
multiple servo-loops.
 A BACKGROUNDER

The task of handling engines was eased by

the introduction of electronic control in the
form of magnetic amplifiers in early civil
and military aircraft.
 A BACKGROUNDER
The magnetic amplifiers allowed engines to
be stabilized at any speed in the throttle
range by introducing a servo-loop with
engine exhaust gas temperature as a
measure of engine speed and an analogue
fuel valve to control fuel flow.
 A BACKGROUNDER

Transistors, integrated circuits and high

temperature semi-conductors have all
played a part in the evolution of control
systems from range temperature control
through to full digital engine control
systems.
 A BACKGROUNDER

This allowed the pilot to accelerate and

decelerate the engine while the control
system limited fuel flows to prevent over-
speeds or excessive temperatures.
 A BACKGROUNDER

With modern FADEC systems there are no

mechanical control rods or mechanical
reversions, and the pilot can perform
carefree handling of the engine throughout
the flight envelope.
 A BACKGROUNDER

On modern aircraft the engine is supervised

by a computer to allow the pilot to operate at
maximum performance in a combat aircraft
or at optimum fuel economy in a passenger
carrying aircraft.
 A BACKGROUNDER

Today, each FADEC is unique and therefore

is expensive to develop, produce, maintain,
and upgrade for its particular application.
 A BACKGROUNDER

In the future, it is desired to establish a

universal or common standard for engine
controls and accessories. This will
significantly reduce the high development
and support costs across platforms.
 LOCATION OF FADEC

FADEC is normally located on the engine fan

casing. Therefore, FADEC cooling is difficult.
 LOCATION OF FADEC

However, there are many features of engine

control which are distributed around the
engine – such as reverse thrust, presently
pneumatically actuated – which would need to
be actuated by alternative means in a more-
electric engine. This leads to the possibility of
using distributed engine control.
 ELECTRONIC ASPECTS OF FADEC

Modern ECUs use a microprocessor which can

process the inputs from the engine sensors in
real time. An electronic control unit contains
the hardware and software (firmware).
 ELECTRONIC ASPECTS: FADEC

The hardware consists of electronic

components on a printed circuit board
(PCB), ceramic substrate or a thin laminate
substrate. The main component on this
circuit board is a microcontroller chip
(CPU).
 ELECTRONIC ASPECTS : FADEC

The software is stored in the microcontroller

or other chips on the PCB, typically in EPROMs
or flash memory so the CPU can be re-
programmed by uploading updated code or
replacing chips. This is also referred to as an
Electronic Engine Management System (EMS).
 HOW DOES FADEC WORK?

FADEC works by receiving multiple input

variables of the current flight condition
including air density, throttle lever position,
engine temperatures, engine pressures, and
many others.
 HOW DOES FADEC WORK?

Each FADEC is essentially a centralized

system, with a redundant, central computer
and centrally located analog signal interfacing
circuitry for interfacing with sensors and
actuators located throughout the propulsion
system.
 HOW DOES FADEC WORK?

Engine operating parameters such as fuel

flow, stator vane position, bleed valve
position and others are computed from this
data and applied as appropriate.
 HOW DOES FADEC WORK?

For example, to avoid exceeding a certain

engine temperature, the FADEC can be
programmed to automatically take the
necessary measures without pilot
intervention.

The inputs are received by the EEC and

analyzed up to 70 times per second.
 HOW DOES FADEC WORK?

FADEC computes the appropriate thrust

settings and applies them.

During flight, small changes in operation are

constantly being made to maintain efficiency.

Maximum thrust is available for emergency

situations if the throttle is advanced to full, but
remember, limitations can’t be exceeded.
 HOW DOES FADEC WORK?

Another new feature of the FADEC system is

the ability to record the last 900 hours of flight.

With readings taken every second, this stored

information can be used to diagnose problem
areas as well as review recent flight history.
 FADEC : FUNCTIONS
AIRFRAME ENGINE CONTROL
COMMUNICATION

REPORT ACQUIRE
ENGINE STATUS SENSOR DATA

RECEIVE ENGINE PROCESS

POWER COMMAND
FADEC CONTROL LAWS

COMMAND
ACTUATORS

ENGINE HEALTH
MONITORING

DIAGNOSTIC

PROGNOSTIC

ADAPTIVE
 FADEC : ESSENTIAL
FEATURES
- Control & Monitoring of Engine Operations
- Dual Channels & Redundancy
- Engine Life Monitoring
- Record of Engine Performance Parameters
- Automated Troubleshooting
- Memory Read or Recall of Engine Data
- Control of Common Engine Problems
- Display of Warnings
- Adaptation
- Isochronous Idle Speed
 FADEC :INFRASTRUCTURE
CONTROL OPERATIONS IN GAS TURBINE ENGINES
 FADEC: INFRASTRUCTURE
CONTROL OPERATIONS IN GAS TURBINE ENGINES
- Air Control (Compressor Entry)

- Fuel Control (Main / AB / Starting System)

- Starting & Ignition Control

- Lubrication Control

- Surge Control (Through Bleed Valve)

- Thrust Control (Through Exhaust Nozzle)

- Vibration Control (Through Air / Fuel Control)

 FADEC: INFRASTRUCTURE
SAMPLE CHAIN OF CONTROL (MECH.) OPERATION

GEAR DRIVEN WORKING FLUID ACTUATED

MECHANICAL PUMP FROM ASSEMBLY
ENGINE / AIRCRAFT

ELECTRO-HYDRO-MECHNICAL MECHANICAL
CONTROL UNIT
ACTUATORS
SERVO POSITION POSITION
POSITION SOLENOID
ACTUATING
SENSORS VALVES SENSOR-1 SENSOR-2
MOTORS

FADEC COMPUTER

AIRCRAFT COMPUTER COCKPIT

 FADEC : INFRASTRUCTURE
SAMPLE CHAIN OF CONTROL (ELECT.) OPERATION
MECHANICAL
ACTUATORS
ELECTRO-HYDRO-MECHNICAL
CONTROL UNIT POSITION POSITION
SERVO SENSOR-1 SENSOR-2
POSITION SOLENOID
ACTUATING
SENSORS VALVES
MOTORS

FADEC
COMPUTER

PILOT’s THROTTLE
VARIOUS INPUTS IN COCKPIT
FROM AIRCRAFT
POWER DISPLAY PANEL
SUPPLY IN COCKPIT

VARIOUS INPUTS FROM /

COMMANDS TO ENGINE
 FADEC: INFRASTRUCTURE
HARDWARE:

- Dual Power Supply

- FADEC Computer (With Logic Circuit PCBs & Programmed /
Programmable Memory)
- A Set of Servo Actuating Motors / Solenoid Valves / Position
Sensors (for every System Control Unit)
- Dual Position Sensors for Actuators (of every System)
- A Set of Electrical Harnesses (for every System)
- Display Panel with Indicators / Warning Lights (in Cockpit)
- Multiple Engine RPM, Pressure Sensors & Thermocouples
- Pilot’s Throttle
 FADEC : INFRASTRUCTURE
SOFTWARE:
- EPR Schedules (For Thrust, over Entire Range of
Engine Operation Without FADEC Computer Failure)

- N Schedules (For Thrust as per Pilot’s Throttle,

Engine Operation in case of Limited FADEC
Computer Functionality)
Note: In case of certain degree of FADEC failure,
there is an automatic mode switch-over from EPR to
N rating. However, if the failure disappears, the
pilot can reset the mode to switch-back to EPR
mode.
 FADEC: INFRASTRUCTURE
INPUTS:

From Aircraft.

- Ambient Temperature
- Altitude
- Mach Number
- Angle of Attack
- Impact Pressure
- Landing Gear Position
- Missile / Rocket Firing Signals etc.
FADEC: INFRASTRUCTURE
INPUTS:

From Engine.

- Throttle Lever Position

- RPM
- Turbine Outlet / Exhaust Gas Temperature
- Exhaust Nozzle Area
- Fan Duct Flaps Position
- Bearing Temperatures
- Engine Vibration
- Engine Pressures
 FADEC: INFRASTRUCTURE
SIMPLIFIED FADEC ARCHITECTURE

FADEC LANE-A FADEC

LANE-A
FADEC MONITOR
LANE-A
CONTROL
ENGINE ENGINE
THRUST FADEC LANE-B FADEC FUEL
DEMAND LANE-B DEMAND
FADEC MONITOR
LANE-B
CONTROL
 FADEC: INFRASTRUCTURE
SIMPLIFIED FADEC ARCHITECHTURE

This simplified architecture is typical of

many dual-channel FADECs.

There are two independent lanes: Lane A

and Lane B.
 FADEC: INFRASTRUCTURE
SIMPLIFIED FADEC ARCHITECHTURE

Each lane comprises a Command and

Monitor portion, which are interconnected
for cross monitoring purposes, and
undertakes the task of metering the fuel
flow to the engine in accordance with the
necessary control laws to satisfy the flight
crew thrust command.
 FADEC: INFRASTRUCTURE

SIMPLIFIED FADEC ARCHITECHTURE

The analysis required to decide upon the

impact of certain failures in conjunction
with others, requires a Markov model in
order to be able to understand the
dependencies.
 FADEC : INFRASTRUCTURE
MARKOV ANALYSIS MODEL

•By using this model the effects of

interrelated failures can be examined.

•The model has a total of 16 states as

shown by the number in the bottom right-
hand corner of the appropriate box.
 FADEC : INFRASTRUCTURE
MARKOV ANALYSIS MODEL

•Each box relates to the serviceability state of

the Lane A Command (Ca) and Monitor (Ma)
channels and Lane B Command (Cb) and
Monitor (Mb) channels.
 FADEC : INFRASTRUCTURE
MARKOV ANALYSIS MODEL

•These range from the fully serviceable state in

box 1 through a series of failure conditions to the
totally failed state in box 16.

•Clearly most normal operating conditions are

going to be in the left-hand region of the model.
 FADEC : INFRASTRUCTURE
MARKOV MODEL ANALYSIS

CaMa.CbMb 6

CaMa.CbMb 2 CaMa.CbMb 7 CaMa.CbMb 12

CaMa.CbMb 3 CaMa.CbMb 8 CaMa.CbMb 13

CaMa.CbMb 1 CaMa.CbMb 16

CaMa.CbMb 4 CaMa.CbMb 9 CaMa.CbMb 14

CaMa.CbMb 5 CaMa.CbMb 10 CaMa.CbMb 15

CaMa.CbMb 11

NO FAILURE 1 FAILURE 2 FAILURES 3 FAILURES

4 FAILURES

DISPACHABLE CONTROLLABLE ENGINE

ENGINE ENGINE SHUT-DOWN
FADEC: INFRASTRUCTURE
Concentrating on the left-hand side of the model it
can be seen that the fully serviceable state in box 1
can migrate to any one of six states:

– Failure of Command channel A results in state 2

being reached.
– Failure of Monitor channel A results in state 3
being reached.
– Failure of Command channel B results in state 4
being reached.
– Failure of Monitor channel B results in state 5
being reached.
– Failure of the cross-monitor between Command A
and Monitor A results in both being lost
simultaneously and reaching state 6.
– Failure of the cross-monitor between Command B
and Monitor B results in both being lost
simultaneously and reaching state 11.
FADEC: INFRASTRUCTURE

All of these failure states result in an engine

which may still be controlled by the FADEC.
However, further failures beyond this point
may result in an engine which may not be
controllable either because both control
channels are inoperative or because the
‘good’ control and monitor lanes are in
opposing channels or worse.
FADEC: INFRASTRUCTURE

The model shown above is constructed

according to the following rules: an engine
may be dispatched as a ‘get-you-home’
measure provided that only one monitor
channel has failed.

This means that states 3 and 5 are

dispatchable: but not states 2, 4, 6, or 11 as
subsequent failures could result in engine
shut-down.
FADEC: ESSENTIAL FEATURES

MILITARY / TRANSPORT AIRCRAFT

- Compressor Entry Guide Vanes Control
(For LP Compressor & HP Compressor)
- Main Fuel Control
- AB Fuel Control (For Core & Fan AB)
- Starting Fuel Control & Ignition Control
- Bleed Valve Control & Fan Duct Flaps
Control
- Exhaust Nozzle Control
- Lubrication Control & Vibration Control
FADEC : SCHEMATIC DIAGRAM
LP COMPRESSOR
STARTING AIR EGV CONTROL
&
IGNITION HP COMPRESSOR
CONTROL AIR EGV CONTROL
POWER MAIN FUEL
SUPPLY CONTROL
CORE AB FUEL
CONTROL
EECU
AIRCRAFT
FADEC FAN AB FUEL
CONTROL
COMPUTER
EXHAUST NOZZLE
CONTROL

FAN DUCT FLAPS

CONTROL

PILOT BLEED VALVE

IN CONTROL
COCKPIT
CENTRALIZED CONTROL ARCHITECTURE
Each function residesCentralized Engine
within the FADEC Control
and uses unique point-to-point analog
connections to system effectors.
Sensor
electronics Sensor_1
Sensor
electronics
Sensor_2
Communication

Sensor
Communication electronics
Sensor_ j

CPU /
BUS

Memory
Actuation Actuator_n
electronics

Power Actuation Actuator_2

electronics
Actuation
electronics Actuator_1
FADEC
DISTRIBUTED CONTROL ARCHITECTURE
Functions are distributed outside of the
Centralized FADECControl
Engine and communicate via a
common interface standard.

Sensor
electronics Sensor_1

Sensor
electronics Sensor_2
Communication

Communication
Sensor
electronics Sensor_ j

CPU /
BUS

Memory Actuation
electronics Actuator_n

Actuation
Power electronics Actuator_2

Actuation
electronics Actuator_1
FADEC
FADEC : ADVANTAGES
- Reduced Aircrew Workload.
- Improved Fuel Efficiency up to 15%
(Due to faster, Accurate Engine
Control no trimming is required).
- Reduced Aircraft Weight and Engine
Size (Due to Absence of Heavy
Mechanical Assemblies, No
Scattering of Pipelines & Electrical
Wirings).
- Enhanced Engine Life (Due to Engine
Operation in Safer / Mean Range).
- Improved Reliability (Due to
Redundancy and Dual Channel).
FADEC : ADVANTAGES

- Minimum Maintenance due to On Board

Computer Guided Troubleshooting
(Aircraft can return to Flying at the
Earliest).

- Isochronous Idle speed leads to

Smoother Engine Starts.
FADEC : ADVANTAGES

- Maximum Performance in a combat

aircraft or at Optimum Fuel Economy
in a Transport Aircraft are possible
after necessary Adaptation /
Programming of FADEC Computer.

- Auto-testing removes the need for

test-running the engine after minor
maintenance work ( Resulting in
annual savings of millions of gallon of
fuel for the fleet.
FADEC : LIMITATIONS
- Pilot can not override the FADEC
Control.

- In the event of complete FADEC

Failure, pilot left with no other option
than having to fly with least
performance, just sufficient to land
safely. (This limitation has been
removed in modern transport
aircraft by having two FADEC
Computers.)
FADEC: ANY QUESTION