Computational Tool for Aircraft Fuel System Analysis

Abstract

Fuel level gauging in aircraft presents a significant flight mechanics challenge due to the influence of aircraft movements on measurements. Moreover, it constitutes a multidimensional problem where various sensors distributed within the tank must converge to yield a precise and single measurement, independent of the aircraft’s attitude. Furthermore, fuel distribution across multiple tanks of irregular geometries complicates the readings even further. These issues critically impact safety and economy, as gauging errors may compromise flight security and lead to carrying excess weight. In response to these challenges, this research introduces a multi-stage project in aircraft fuel gauging systems, as a continuum of studies, where this first article presents a computational tool designed to simulate aircraft fuel sensor data readings as a function of fuel level, fuel tank geometry, sensor location, and aircraft attitude. Developed in an open-source environment, the tool aims to support the statistical inference required for accurate modeling in which synthetic data generation becomes a crucial component. A discretization procedure accurately maps fuel tank geometries and their mass properties. The tool, then, intersects these geometries with fuel-level planes and calculates each new volume. It integrates descriptive geometry to intersect these fuel planes with representative capacitive level-sensing probes and computes the sensor readings for the simulated flight conditions. The method is validated against geometries with analytical solutions. This process yields detailed fuel measurement responses for each sensor inside the tank, and for different analyzed fuel levels, providing insights into the sensors’ signals’ non-linear behavior at each analyzed aircraft attitude. The non-linear behavior is also influenced by the sensor saturation readings at 0 when above the fuel level and at 1 when submerged. The synthetic fuel sensor readings lay the baseline for a better understanding on how to compute the true fuel level from multiple sensor readings, and ultimately optimizing the amount of used sensors and their placement. The tool’s design offers significant improvements in aircraft fuel gauging accuracy, directly impacting aerostructures and instrumentation, and it is a key aspect of flight safety, fuel management, and navigation in aerospace technology.