Oil System Study24Apr2013

8/11/2019 Oil System Study24Apr2013

1/39

Novel Oil System Trade

StudyRajesh Kudikala Supervisor:DHPA PhD student Professor Peter J Fleming

Rolls-Royce:Vijay PatelAdam McLoughlinIan A Gri!n


2/39

Novel Oil System Trade Study

FBH

IGB (Front)

IGB (Rear)

IP/HP

SAGB

TGB

AGB

TBH

Breather

Scavenge Point

Trent XWB Oil

System Scavenge

Points

NB. Illustration shows Trent 1000

AGB Accessory Gear BoxFBH Front Bearing HousingIGB Internal Gear BoxSAGB Step Aside Gear Box

TBH Tail Bearing HousingTGB Transfer Gear Box

Oil system on Trent XWB engine

Goals Novel oil system for Trent

engines

To improve controllability

of the oil flow to eachchamber

Satisfy the oil systemfunctional requirements

Without compromising

Safety (avoid oil leakingsituation when scavengingfails)


3/39

Baseline Oil System

Architecture

Pump Drive

Pad

Feed Pump

Element

Scavenge

Elements

Oil Chambers

Cooler Elements

Oil Tank

`

Delta

P

FBHIGB

REAR

T

ScavengeFeed

Measurement

Air / Vent

PRV

Strainer

EMCD

125u

FOHE

Feed restrictor

Spill valve

I

GB

FRONT

HP IP TBH BREATHER

AGB TGB SAGB

Oil Bypass Valve

AOHE

AOHE

Delta

P

Delta

P15u

AGB

AGB Accessory Gear BoxAOHE Air/Oil Heat ExchangerEGB External Gear BoxEMCD Electro Magnetic Chip DetectorFBH Front Bearing HousingFOHE Fuel/Oil Heat ExchangerIGB Internal Gear BoxPRV Pressure Relief Valve

SAGB Step Aside Gear BoxTBH Tail Bearing HousingTGB Transfer Gear Box

Baseline oil system Partially pressurised oil

system

Single feed pump and gangedscavenge pumps are driven

by accessory gear box (AGB)with single shaft

Oil flow is proportional toengine speed and have nocontrol of oil flow to

individual chamber

Safety is ensured withcombined feed and scavengepump drive


4/39

Architecture Options

1176 (1 x 7 x 3 x 7 x 2 x 2 x 2) possible architecture options

Means

NOS_4.1 Contain oil

partially pressurised

system via tanks &

pipes

Feed oil during normal operation

Single Mech feed

pump

Single electric feed

pump

Individual electric

feed pump

Zonal ganged electric

feed Pump

Zonal feed pump Main feed + indiv

chamber flow control

pump

Schedule oil during normal operation

Fixed Displacement

Pump

Veriable

Displacement Pump

Variable Restrictor

per chamber

NOS_3.3 Remove aerated oil from chamber sumpSingle Ganged Mech

FD scav pump

drain chamber via

gravity

Single Ganged

electric FD s cav

pump

Individual electric FD

scav pump


FD scav Pump

Zonal ganged FD

scav Pump - elec-

mech mix

Combined Feed &

Scavenge

Separate Feed &

Scavenge

NOS_7.4 Remove debris from oil

Mesh filter Electric charge

across oil flow

NOS_7.5 Limit static charge build up

Earth bond every

component

Electrical bonding for

rotating parts (eg.

Brushes)

Means

NOS_5.1 Control gulp during start upprovide sufficient tank

capacity

electric driven pump variable displacement

mech pump

NOS_5.2 Control gulp during engine transientsprovide sufficient tank

capacity


mech pump

NOS_5.3 Schedule oil flow during engine crankingmechanical fixed

diaplacement feed

pump

mechanical variable

diaplacement feed

pump

electrical fixed

diaplacement feed

pump

variable restrictor separate electric feed

pump per chamber

NOS_5.5Schedule oil flow during and post shut

down

mechanical fixed

diaplacement feed

pump

mechanical variable

diaplacement feed

pump

electrical fixed

diaplacement feed

pump


pump per chamber

NOS_5.6 Schedule oil flow during windmillmechanical fixed

diaplacement feed

pump

mech variable

displacement pump

electric fixed

displacement feed

pump

alternate backup feed

pump driven from LP

shaft

separate electric feed

pump per chamber

NOS_6.6 Ensure system is primedPosition t ank above

pump(s)

drive oil prior to

engine rotation

Prime Function

NOS_5.4

Alternate Mode Function

NOS_

5-TransportOil

NOS_

4-ContainOil

Single elecAC motorfeed pump

Single elecAC motorscav pump

Primary

Functions

Alternate ModeFunctions


5/39

Set of 21 Candidate Architectures studiedMeans

NOS_4.1 Contain oil


system via tanks &

pipes

Feed oi l during normal operation

Single Mech feed

pump

Single electric feed

pump

Individual electric

feed pump


feed Pump

Zonal feed pump Main feed + indiv

chamber flow control

pump


Fixed Displacement

Pump

Veriable

Displacement Pump

Variable Restrictor

per chamber

NOS_3.3 Remove aerated oil from chamber sump

Single Ganged Mech

FD scav pump

drain chamber via

gravity

Single Ganged

electric FD sc av

pump


scav pump


FD scav Pump

Zonal ganged FD

scav Pump - elec-

mech mix

Combined Feed &

Scavenge

Separate Feed &

Scavenge

NOS_7.4 Remove debris from oil

Mesh filter Electric c harge

across oil flow


Earth bond every

component

Electrical bonding for

rotating parts (eg.

Brushes)

Means

NOS_5.1 Control gulp during start upprovide sufficient tank

capacity


mech pump

NOS_5.2 Control gulp during engine transientsprovide sufficient tank

capacity


mech pump

NOS_5.3 Schedule oil flow during engine crankingmechanical fixed

diaplacement feed

pump

mechanical variable

diaplacement feed

pump

electrical fixed

diaplacement feed

pump


pump per chamber

NOS_5.5Schedule oil flow during and post shut

down

mechanical fixeddiaplacement feed

pump

mechanical variablediaplacement feed

pump

electrical fixeddiaplacement feed

pump

variable restrictor separate electric feedpump per chamber

NOS_5.6 Schedule oil flow during windmillmechanical fixed

diaplacement feed

pump

mech variable

displacement pump

electric fixed

displacement feed

pump

alternate backup feed

pump driven from LP

shaft

separate electric feed

pump per chamber

NOS_6.6 Ensure system is primedPosition tank above

pump(s)

drive oil prior to

engine rotation

Prime Function

NOS_5.4

Alternate Mode Function

NOS_

5-

TransportOil

NOS_

4-ContainOil

!"#$%&'$

()*+ - . /

()*+ 0

()*+ 1

()*+ 2

()*+ 3

()*+ 4

()*+ 5

()*+ 6

()*+ -7

()*+ --

()*+ -/

()*+ -0

()*+ -1

()*+ -2

()*+ -6

()*+ /7

()*+ -3

()*+ -4

()*+ -5

()*+ /-

Primary Functions

Alternate ModeFunctions


6/39

DecisionVariables Model

Criteria /

Objectivefunctions

1. Weight (delta)2. Reliability3. Safety

4. Technology Maturity5. Flow Matching

6. Maintenance (delta)

Mechanical / electric pump driveFixed disp / variable disp pumpsFixed / variable flow restrictors

Combined / separate oil feed andscavenge

Ganged / individual oil feed andscavenge

Oil System Optimization Model

1176 Candidate oilsystem architectures

Function means analysis (FMA)

Many objectives,

Discrete variables,

Qualitative & quantitative assessment,

Large discontinuous design space.

Challenges


7/39

Criteria for Oil system trade

studyCriteria Qualitative Rating Rating

!Weight 0

Reliability0

Safety 0

Technology

Maturity0

Flow matching 0

!Maintenance 0


8/39


9/39

ReliabilityIssue Rating

Addition of motor drive reduces reliability-1 x

#drives

Addition of Variable Displacement Pump (VDP) reducesreliability

-1

Removal of drive train increases reliability +1

Use of multiple feed pumps reduces reliability -3

Use of variable restrictor (VR) valves likely to reducereliability

-1

Separate drive for feed and scavenge reduce reliability -1

Separate pressurisation and flow control pumps reducereliability

-3

Use of jet pressure relief valves reduce reliability -1

Issue Rating

Feed and Scavenge are independently drive hence

allowing potential for feed without scavenge-3

Single motor + drive increases fire hazard -1

Multiple motor + drive significantly increases fire

hazard

-3

Safety

Issue Rating

Requires development of AC motor -1

Similar motor/controller & pump has been

demonstrated on POA therefore low technology risk-1

Similar pump demonstrated on POA. Development

of VR + integrated control required-3

VR + electric pump + integrated control need

developing-3

electric pump + distributed control need

development-3

electric pump + complex distributed control need

development-9

Similar motor/controller & pump has been

demonstrated on POA

No experience of check valve driven jets

-3

Issue Rating

Means for fully controlled oil flow per chamber +9

Means for partially controlled oil flow per chamber +3

Slight improvement on baseline +1

No improvement on baseline flow control 0

Issue Rating

Addition of electric driven system improves fault finding able to run oil system independent of engine

+1

Addition of multiple units increases maintainability burdendue to multiple units

-3

Improved EHM capability via electric motor driven solutions +1

Maintenance

Technology Maturity

Flow matching capability


10/39

Primary Functions Options / Means

Contain oilPartially pressurised system via

tanks & pipesBaseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0

Single mechanical fixed

displacement (FD) feed pumpBaseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0

Single electric FD feed pump (AC

motor without controller)Slight increase on baseline -1

Slightly reduced reliability due

to single electric motor -1-1

Slight reduction in safety Single

motor + drive-1

Requires development of AC

motor low technology risk-1

Flow dependent on electrical

frequency (proportional to

engine speed)

0Electric motor slightly reduce

maintenance1

Single electric FD feed pump (DC

motor with controller)Moderate increase on baseline

motor & controller-2


to single electric motor -1 ,

sensor -1-2


motor + drive-1

Similar motor/controller & pump

has been demonstrated on

POA therefore low technology-1

Slight improvement on flow

independent of engine speed2

Slight reduction in maintenance

requirement with electric motor1

Zonal ganged DC electric FD feed

pumpModerate increase on baseline -3

Moderately reduced reliability

due to multi motor -2, sensors

-1, multi feed pumps -1-4

Moderate reduction in safety

multiple motor + drive-3




Moderate improvement on flow

with multi feed pump


Multiple motors and pumps

slightly increase maintenance

from baseline-1

Zonal feed pump electric &

mechanical mixModerate increase on baseline -2


due to single electric motor -1 ,

sensor -1 multi feed pump -1-3


motor + drive-1





with multi feed pump




from baseline-1

Main feed + individual chamber

flow control pumpSignificant increase on

baseline due to multi motors-8



-1-3



Significant technology

development needed for

electric pump + complex-8

Significant improvement on

flow independent of engine

speed and can be controlled for8



from baseline-1

Individual DC electric FD feed

pumpSignificant increase on

baseline-8

Significantly reduced reliability


-1, multi feed pumps -2-6



Moderate technology


electric pump + distributed-4

Significant improvement on

flow independent of engine

speed and can be controlled for8



from baseline-1

Mechanical Variable

displacement feed pump (VDP)Slight increase on baseline due

to VDP-1


to Variable Displacement Pump

(VDP) -2-2

No fire hazard due to Variable

displacement pump0

Moderate technology


variable displacement pump-2

Moderate improvement in flow

means for fully controlled oil

flow per chamber3

Slightly increase in

maintenance with VDP from

baseline-1

Fixed orifice feed restrictor per

chamberBaseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0

Variable Restrictor (VR) per

chamberSlight increase on baseline due

to VR valves & controller-1


to use of variable restrictor

(VR) valves -1 & sensors -1-2

No fire hazard due to VR

valves0

Moderate technology

development needed for VR

valves integrated controller-2

Significant improvement of flow

VR to each oil chamber better

control5

Slightly increase in

maintenance with VR from

baseline-1

Single Ganged Mech fixed disp

scav pumpBaseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0

Single ganged elec feed pump

(AC motor without controller)Slight increase on baseline -1


to single electric motor -1-1


motor + drive-1

Requires development of AC

motor low technology risk-1

Flow dependent on electrical

frequency (proportional to

engine speed)0

Electric motor reduce

maintenance1

Single ganged elec FD Scav

pumpModerate weight increase on

baseline motor & controller-2



sensor -1-2


motor + drive-1






Electric motor reduce

maintenance1

Zonal ganged elec FD scav pumpModerate weight increase due

to multi motor and controller-3



-1-3








Multi motors and pumps slightly

increase maintenance from

baseline-1

Zonal ganged FD scav pump elec

mech mixModerate weight increase

motor and controller-2



sensor -1-2


motor + drive-1



POA therefore low technology-1 Slight improvement on flow 1



baseline-1

Individual elec FD scav pumpSignificant increase in weight

due to multi motors-6



-1-3



Moderate technology


electric pump + distributed-4


independent of engine speed

and can be controlled for each2



baseline-1

Drain Chamber via gravity

Moderate weight reduction on

baseline 3 Slightly reduced reliability -2

Moderately increases fire

hazard with scavenge failure -3

No technology development

needed 0 No effect 0 Slightly reduce maintenance 2

Combined Feed and Scavenge Baseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0

Separate Feed and ScavengeWeight comparable to baseline

(Slight reduction with no drive

train)0


to separate drive for feed and

scavenge-1


with indipendent feed and

scavenge allowing potential-3

No technology development

needed0 Slight improvement on baseline 1

Maintenance comparable to

baseline0

Mesh filter Baseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0

Electric charge across oil flow Slight increase on baseline -1 Slightly reduced reliability -1Moderate reduction in safety

due to fire hazard-3

Slight technology development

needed creating electric charge

across oil flow-1 No effect 0

Maintenance comparable to

baseline0

Earth bond every component Baseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0 Baseline 0

Electrical bonding for rotating

parts (eg. Brushes)Slight increase on baseline -1 Slightly reduced reliability -1


due to fire hazard-3

Moderate development needed

for brushes for electric bonding

rotating parts-3 No effect 0

Electric bonding using brushes


from baseline-1

Feed oil during normal

operation

Schedule oil duringnormal operation

Remove aerated oil

from chamber sump

Feed and Scavenge

combined or separated

Remove debris from oil

Limit static charge build

up

Weight (delta) Reliability Safety Technology Maturity Flow matching Maintenance (delta)

Attribute information for options

* These are assumptions and they need to be validated by experts


11/39

Example evaluations

`

Delta

P

FBHIGB

REAR

T

Scavenge

Feed

Measurement

Air / Vent

PRV

Strainer

EMCD

125u

FOHE

Feed restrictor

Spill valve

IGB

FRONT

HP IP TBH BREATHER

AGB TGB SAGB

Oil Bypass Valve

AOHE

AOHE

DeltaP

DeltaP

15u

`

Motor

Control

ler

Motor

Control

ler

Candidate architecture 9Criteria evaluations from attributes information


12/39

1176 Architectures Evaluations

1176


13/39

DecisionVariables Model

Criteria /

Objectivefunctions

Weight (delta)ReliabilitySafety

Technology MaturityFlow MatchingMaintenance (delta)

Selected options for primaryfunction

Multiple objectives &Objectives are conflicting

Performan

ce

f1

f2 0

0

0

0

0

24

1

Oil System Model

Attributes information

Candidate Oil System Architecture

Non-dominated solutions

Means

NOS_4.1 Contain oil


system viatanks &

pipes

Feed oil during normal operation

SingleMech feed

pump

Singleelectric feed

pump

Individual electric

feedpump

Zonal gangedelectric

feedPump

Zonal feedpump Mainfeed+ indiv

chamberflowcontrolpump


FixedDisplacement

Pump

Veriable

Displacement Pump

VariableRestrictor

perchamber

NOS_3.3 Remove aerated oil fromchamber sumpSingleGangedMech

FDscavpump

drainchambervia

gravity

SingleGanged

electric FDscav

pump


scavpump

Zonal gangedelectric

FDscavPump

Zonal ganged FD

scavPump-elec-

mechmix

CombinedFeed&

Scavenge

SeparateFeed&

Scavenge

NOS_7.4 Remove debris fromoil

Meshfilter Electric charge

across oil flow


Earthbondevery

component

Electrical bondingfor

rotatingparts (eg.

Brushes)

_i i i

i

l i i i l i l

_i i i

i

l i i i l i l

_i l i

i l

i l i l

i l

l i l i

i l

i l i l i

_ i l i

i l

i l i l

i l

l i l i

i l

i l i l i

_i l i

i l

i l

i l

l i i

i l

l

i

l i

_ii i i l i

i i

Prime Function

NOS_5.4

-

NOS_

4-ContainOil

Primary Functions


14/39

Non-dominated solutions

Solution A dominates Solution B

Solution C dominates Solution B

Solution A and Solution C are non-dominatedf

1

f2 0

0

0

0

0

2

4

1

2 objective minimisation problem Oil system maximisation problem


15/39

0

0.01

0.02

0.03

0.04

0.05

0.06

MW 1.0 - DIV

5000 i terations

0.578

0.582

0.586

0.59

0.594

0.58 0.6 0.62 0.64

!MW

Diversity

Objec

tive1

Objective 2

Obje

ctiv

e2

Obje

ctive1

Consider 2-objective case

Parallel coordinates representation


16/39


17/39

Trade-o!graph (non-dominated solutions)

Obtained 96Non-

dominated candidatearchitectures

Zero line represents

the baseline solution

Solutions above zeroline are less good forthat particularcriterion

Solutions below zero

line are good for thatparticular criterion

Found several

infeasible architectures

20

10

0

-10

-20

-30


18/39

Infeasible oil system architectures

Individual electric feed

pumps per chamber arecombined with variablerestrictors

Delta

P

FBH

T

Scavenge

Feed

Measurement

Air / VentPRV

Strainer

EMCD

125u

FOHE

Feed restrictor

Spill valve

OilBypass Valve

AOHE

AOHE

DeltaP

15u

`

IGBRear

IGBFront

HPBreather

TBHIP AGB TGB SAGB

C

M

C

M

C

M

C

M

C

M

C

M

C

M

C

M

Motor

Control

ler

Motor

Control

ler

`

Delta

P

FBHIGB

REAR

T

Scavenge

Feed

Measurement

Air/ Vent

PRV

Strainer

EMCD

125u

FOHE

Feed restrictor

Spill valve

IGB

FRONT

HP IP TBH BREATHER

AGB TGB SAGB

OilBypass Valve

AOHE

AOHE

DeltaP

DeltaP

15u

`

Motor

Cont

rol

ler

Motor

Control

ler


19/39

Combined feed and scavenge flow

Feasible architecturesBoth drives

Mechanical

Electrical A/C

Electrical D/C

Individual electric feed

Pump Drive

Pad

Feed Pump

Element

Scavenge

Elements

Oil Chambers

Cooler Elements

Oil Tank

`

Delta

P

FBHIGB

REAR

T

Scavenge

Feed

Measurement

Air / Vent

PRV

Strainer

EMCD

125u

FOHE

Feed restrictor

Spill valve

IGBFRONT

HP IP TBH BREATHER

AGB TGB SAGB

Oil Bypass Valve

AOHE

AOHE

Delta

P

DeltaP

15u

AGB

DeltaP

T

Scavenge

Feed

Measurement

Air/ Vent

PRV

Strainer

EMCD

125u

FOHE

Feed restrictor

Spill valve

OilBypass Valve

AOHE

AOHE

DeltaP 15u

Motor

Control

ler

AGB TGBCM

SAGBCM

Breather

CM

TBHCM

IPCM

HPCM

IGBRear

CM

IGBFrontCM

FBHCM

`

DeltaP

FBHIGB

REAR

T

Scavenge

Feed

Measurement

Air/ Vent

PRV

Strainer

EMCD

125u

FOHE

Feed restrictor

Spill valve

IGB

FRONT

HP IP TBH BREATHER

AGB TGB SAGB

OilBypass Valve

AOHE

AOHE

Delta

P

DeltaP

15u

Motor

AC InductionMotor

Other combinations ofmechanical and electrical drivesare infeasible for combined

feed and scavenge flow


20/39

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21/39

432 Architectures Evaluations

432


22/39


Obtained 40Non-dominated candidatearchitectures

Zero line represents

the baseline solution

Solutions above zero

line are less good forthat particular

criterion

Solutions below zero

line are good for thatparticular criterion


23/39

Cluster analysis 3 clusters have been found

from 40 non-dominatedsolutions

In cluster 1 (red colour) 3

solutions have individualelectric feed and scavengepumps. They are having

significant increase in criteriavalues

In cluster 2 (green colour) 11solutions have better flowcontrollability with increasingweight and safety

In cluster 3 (blue colour) 26solutions have low to mediumflow controllability with lowweight

Gray scale image of re-ordered dissimilarity matrixusing visual assessment of cluster tendency (VAT) method


24/39


25/39


Goal value set for theweight criteria as 9 toreduce the solutions

having heavy weight

compare to baselinesolution

This reduces the

number of non-

dominated solutions to

37architectures


26/39


Here goals are set forthe weight and safetycriteria as 9 and 6

This reduces thenumber of non-

dominated solutions to

28architectures

28 non dominated architectures


27/39

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28 non-dominated architectures


28/39

Candidate architectures 1, 2, 3, 4, 5, 9, 20 and 21

Non-dominated architectures studied in report


29/39

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30/39

Uncertainty handling in performance rating

`

DeltaP

FBHIGB

REAR

T

Scavenge

Feed

Measurement

Air / Vent

PRV

Strainer

EMCD

125u

FOHE

Feed restrictor

Spill valve

IGBFRONT

HP IP TBH BREATHER

AGB TGB SAGB

OilBypass Valve

AOHE

AOHE

DeltaP

Delta

P15u

AGB

AGB

Criteria Qualitative Rating Rating

!Weight Slight increase on baseline -1

Reliability

SingleMotor

(-1)

SepFeed

&

Scav

(-1)

Sensors(-2)

VRValves

(-1)-5

SafetySingle MotorFire (-1)

Split Feed & Scav(-3)

-4

TechnologyMaturity

Similar motor/controller & pump hasbeen demonstrated on POA.

Development of VR valves, VDP and

distributed control required

-3

Flow matching

Significant improvement on baseline asflow is independent of engine speed

and controlled per chamber+9

!Maintenance 0

Uncertainty

U t i t h dli i f ti


31/39

Estimating the uncertainty incriteria evaluations

Compare solutions havinguncertainty

Compute Probability of dominance

Robust design solutions

Uncertainty handling in performance ratingUncertainty


32/39


33/39

Non-dominated solutions withvariance

Example 3 solutions


34/39



35/39

Uncertainty handling in performance rating

2= 0.1

2= 1

Mean

Normal distribution for performancerating

Variance (2)


36/39


S5'.51,& I IW2 IWJ IWM IWN IWO IWP IWQ IWR IWT 2

)*1L8*9.15%&8 $*"#0*1$

J J J Q Q JI JI JI JI JI JI

M M M 2N 2N 2J 2J

N N N 2Q 2Q JR JR

O P P JI JI

P Q Q JO JO

Q R RR T T

T 2I 2I

2I 22 22

22 2J 2J

2J 2M 2M

2M 2N 2N

2N 2O 2O

2O 2Q 2Q

2P 2R 2R

2Q 2T 2T2R JI JI

2T J2 J2

JI JJ JJ

J2 JM JM

JJ JN JN

JM JO JO

JN JP JP

JO JQ JQ

JP JR JR

JQ

JR


37/39


38/39

Conclusions Novel oil system architecture designs for improving the oil flow to each

oil chamber of gas turbine engine has been studied using MCDM

techniques.

Model for evaluating the oil system architectures has been developedusing attribute information.

Infeasible oil system architectures have been removed from search

space. Non-dominated sorting has been performed and 40 non-dominated

architecture solutions have been found from 432 feasible architectures.

Identified 3 clusters of solutions and selected small set of solutions fromclusters.

Uncertainty in the criteria rating of oil system architectures has beenconsidered as Gaussian distributions with di"erent variance values.

Found architecture 20 (oil system with single DC electric FD pump forcombined feed and scavenge flow with variable restrictors) as thepotential robust solution.


39/39

Thanks

Oil System Study24Apr2013

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