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continues a gradual decline through the hardware manufacturing phase through the development and refinement of analysis and simulations. The next significant reduction in uncertainty occurs after FETT with the acquisition of key engine data. Unfortunately, all decisions affecting control system component definition had to be made during the control system design phase when requirement uncertainty was at a moderate to high level. To reduce technical program risk, conservative assumptions are made regarding control system component requirements resulting in sometimes significant product cost and weight impacts. This basic schedule conflict can be summarized by the two shaded boxes on the figure. The one shown on the upper chart represents the point of requirements availability for "normal" system decomposition (i.e. the control system is the last to receive requirements). The shaded box on the lower chart shows that, for a compressed development schedule, the control system is the first engine module to require hardware. Impacts ofnon-optimum product cost and weight result in one of two courses of action. 1. Components are eventually redesigned to optimize critical attributes. In the case of actuators, pistons are downsized reducing weight. In the case of pumps, flow capacity and/or pressure levels are reduced resulting in weight and/or heat load savings. Due to the high non-recurring cost (engineering and flight certification) of initial development, the cost ofredesign is usually quite substantial, ranging in the low $1OOk's for relatively simple parts such as temperature sensors to the millions for complex components such as electronic controls. 2. Components continue into production carrying the burden of unnecessarily high product cost and weight. The impacts of excessive cost and weight are shouldered by the operator in terms of life cycle cost (LCC). LCC or total cost of ownership is comprised of development, production (acquisition), operations, and support costs. Unnecessarily 12PDF Image | Improving Gas Turbine Engine Control System
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