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<p>In turboprop engines, uncontrolled increases in exhaust gas temperature (EGT) have been a significant engineering challenge, resulting in substantial performance losses and an increased risk of thermal damage, particularly in the turbine section. Current engine control systems are unable to accurately predict EGT increases under variable flight conditions, leading to critical issues such as turbine blade overheating, material fatigue, creep, and reduced engine life. The main objective of this study is to develop a Digital Twin (DT)-based EGT control algorithm that addresses EGT in relation to turbine entry temperature (TET) and possesses real-time adaptation capabilities, thereby overcoming the aforementioned challenges. In the study, a virtual copy of the turboprop engine was created using the DT methodology. This model was continuously updated with real-time sensor data, and the engine’s performance was monitored under various flight conditions. In the optimized control strategy, EGT and fuel flow were considered simultaneously, with a multi-objective control approach that maintained turbine temperature within safe limits and suppressed sudden fluctuations in fuel flow. The suggested method was compared with traditional EGT control approaches, demonstrating that DT-based control offers superior thermal stability and performance. The results obtained demonstrate that the EGT, which reached approximately 1200&#xa0;K before the control algorithm was applied, could be reduced to approximately 900&#xa0;K using the developed DT-based EGT control algorithm. This improvement has significantly reduced thermal stress on the turbine, increased engine efficiency, and improved fuel supply balance. In conclusion, this study demonstrates, through comparative results, that DT technology is an effective tool for controlling EGT and improving fuel performance in turboprop engines, providing a strong foundation for future predictive maintenance and performance optimization studies. Furthermore, the developed control algorithm has a structure that is suitable for further improvement using more advanced methods.</p>

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Comprehensive analysis of turboprop engine performance across various flight conditions with exhaust gas temperature fluctuations using digital twin technology

  • 期刊论文

  • 发表日期：

    2026年6月16日

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  • Elif Zeyneb Tekin,
  • Melih Yıldız,
  • Utku Kale,
  • Artūras Kilikevičius

摘要

In turboprop engines, uncontrolled increases in exhaust gas temperature (EGT) have been a significant engineering challenge, resulting in substantial performance losses and an increased risk of thermal damage, particularly in the turbine section. Current engine control systems are unable to accurately predict EGT increases under variable flight conditions, leading to critical issues such as turbine blade overheating, material fatigue, creep, and reduced engine life. The main objective of this study is to develop a Digital Twin (DT)-based EGT control algorithm that addresses EGT in relation to turbine entry temperature (TET) and possesses real-time adaptation capabilities, thereby overcoming the aforementioned challenges. In the study, a virtual copy of the turboprop engine was created using the DT methodology. This model was continuously updated with real-time sensor data, and the engine’s performance was monitored under various flight conditions. In the optimized control strategy, EGT and fuel flow were considered simultaneously, with a multi-objective control approach that maintained turbine temperature within safe limits and suppressed sudden fluctuations in fuel flow. The suggested method was compared with traditional EGT control approaches, demonstrating that DT-based control offers superior thermal stability and performance. The results obtained demonstrate that the EGT, which reached approximately 1200 K before the control algorithm was applied, could be reduced to approximately 900 K using the developed DT-based EGT control algorithm. This improvement has significantly reduced thermal stress on the turbine, increased engine efficiency, and improved fuel supply balance. In conclusion, this study demonstrates, through comparative results, that DT technology is an effective tool for controlling EGT and improving fuel performance in turboprop engines, providing a strong foundation for future predictive maintenance and performance optimization studies. Furthermore, the developed control algorithm has a structure that is suitable for further improvement using more advanced methods.