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PW/HS validation process works in a very similar manner beginning with design verification testing at the component level, followed by subsystem (control system hardware and software) integration testing on the Closed-Loop Bench, leading up to full-up engine test. Depending on the complexity of the component, design verification testing can take anywhere from a few days for very simple parts with only a few functional requirements, to months for complex components such as fuel controls or electronic controls. Once certain key hardware and software components have completed design verification testing at the component level, they are assembled onto a system bench where they are tested in an integrated environment with a "closed-loop" computerized engine model. This is signified by symbol j) on Figure 4-3. This is a key activity in the functional verification process of the control system and serves to significantly reduce the risk to FETT by verifying proper hardware/software integration and adequate software maturity in a low-risk environment (i.e. software errors can be uncovered, evaluated, and corrected without putting millions of dollars worth of experimental engine hardware at risk). Since the engine is simulated, however, there is little opportunity to resolve many areas of uncertainty associated with engine-driven requirements such as actuation loads and surge margin. These types of uncertainty can only be resolved by running an actual engine. Finally, 18-24 months and millions of dollars after program launch, the first heavily instrumented engine is assembled, installed into a development test stand, and started for the first time. Initial testing focuses on vibration surveys, aeromechanical stress of the turbomachinery, and component (i.e. major engine module) performance verification. Once confidence is built with the steady-state operation of the machine, throttle transients are gradually made faster until snap transients (throttle movements in less than one second) are achieved. This development process normally begins at or near sea-level conditions in an open-air test stand and is often 75PDF Image | Improving Gas Turbine Engine Control System
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