Patent Grant
12209502
The present disclosure relates generally to gas turbine engines, and more specifically to fan assemblies for gas turbine engines.
Gas turbine engines are used to power aircraft, watercraft, power generators, and the like. Gas turbine engines typically include a compressor, a combustor, and a turbine. The compressor compresses air drawn into the engine and delivers high pressure air to the combustor. In the combustor, fuel is mixed with the high pressure air and is ignited. Products of the combustion reaction in the combustor are directed into the turbine where work is extracted to drive the compressor and, sometimes, an output shaft. Left-over products of the combustion are exhausted out of the turbine and may provide thrust in some applications.
In embedded gas turbine engine applications, the engine may experience high distortion in the form of pressure gradients and swirl. The pressure and swirl distortions may cause engine stall or other undesirable aeromechanical behavior. The fan of the gas turbine engine may include mitigation systems to reduce or minimize the negative effects of pressure and swirl distortions to improve stall margin of the engine.
The present disclosure may comprise one or more of the following features and combinations thereof.
A fan case assembly is adapted for use with a gas turbine engine. The fan case assembly comprises a case, a plurality of drums, and a control unit.
The case extends circumferentially at least partway about a central axis of the fan case assembly to define an outer boundary of a gas path of the gas turbine engine. A plurality of grooves extend axially at least partway between an axially forward end of the fan case and an axially aft end of the fan case.
Each one of the plurality of drums is disposed in a corresponding one of the plurality of grooves of the fan case and spaced circumferentially about the central axis. Each drum of the plurality of drums includes a forward portion and an aft portion rotatably connected to the forward portion. The forward portion and aft portion are each shaped to form a respective axial passageway.
The forward portion and the aft portion of each drum of the plurality of drums are configured to rotate about a respective drum axis between a closed position and an open position. In the closed position, the forward portion and the aft portion are positioned to block fluid communication between the forward axial passageway and the aft axial passageway. In the open position, the forward portion and the aft portion are positioned to allow fluid communication between the forward axial passageway and the aft axial passageway.
The control unit is configured to rotate the plurality of drums about the respective drum axis between the closed position and the open position in response to preselected operating conditions to minimize negative effects pressure and swirl distortions in the gas turbine engine to improve stall margin.
In some embodiments, the forward axial passageway extends axially along the drum axis of the forward portion from near a forward end surface of the forward portion through an aft end surface of the forward portion to create an aft end opening of the forward axial passageway.
In some embodiments, the aft axial passageway extends axially along the drum axis of the aft portion from near an aft end surface of the forward portion through a forward end surface of the aft portion to create a forward end opening of the aft axial passageway.
In some embodiments, in the open position, the forward end opening of the aft axial passageway and the aft end opening of the forward axial passageway align to allow fluid communication between the forward axial passageway and the aft axial passageway.
In some embodiments, in the closed position, the forward end opening of the aft axial passageway and the aft end opening of the forward axial passageway are positioned to block fluid communication between the forward axial passageway and the aft axial passageway.
In some embodiments, the forward portion is shaped to form a forward aperture in an outer surface of the drum. The forward aperture is disposed near a forward end of the drum and in fluid communication with the forward axial passageway.
In some embodiments, the aft portion is shaped to form an aft aperture in an outer surface of the drum. The aft aperture is disposed near an aft end of the drum and in fluid communication with the aft axial passageway.
In some embodiments, in the open position, each of the plurality of drums is positioned to face the forward aperture and the aft aperture towards the gas path to allow fluid communication between the gas path, the forward aperture, the forward axial passageway, the aft axial passageway, and the aft aperture.
In some embodiments, the case includes a circumferential channel. The plurality of grooves intersect the circumferential channel.
In some embodiments, the plurality of drums includes a first drum in a first groove and a second drum in a second groove. A portion of the circumferential channel extends between the first drum and the second drum.
In some embodiments, at least one of the forward portion and the aft portion is shaped to form a T shaped passageway disposed near an end of the drum in fluid communication with the respective axial passageway.
In some embodiments, in the open position, a first portion of the T shaped passageway is aligned with the circumferential channel. A second portion of the T shaped passageway faces radially towards the gas path to allow fluid communication between the gas path and the T shaped passageway.
In some embodiments, in a bypass position, a first portion of the T shaped passageway is aligned with the circumferential channel on both sides of the corresponding drum and a second portion of the T shaped passageway faces radially away from the gas path to block fluid communication between the T shaped passageway and the gas path.
In some embodiments, a gas turbine engine comprises a fan and a fan case assembly. The fan includes a fan rotor configured to rotate about an axis of the gas turbine engine and a plurality of fan blades coupled to the fan rotor for rotation therewith. The fan case assembly is adapted for use with the gas turbine engine. The fan case assembly comprises a case, a plurality of drums, and a control unit.
The case extends circumferentially at least partway about a central axis of the fan case assembly to define an outer boundary of a gas path of the gas turbine engine. A plurality of grooves extend axially at least partway between an axially forward end of the fan case and an axially aft end of the fan case.
Each one of the plurality of drums is disposed in a corresponding one of the plurality of grooves of the fan case and spaced circumferentially about the central axis. Each drum of the plurality of drums includes a forward portion and an aft portion rotatably connected to the forward portion. The forward portion and aft portion are each shaped to form a respective axial passageway.
The forward portion and the aft portion of each drum of the plurality of drums are configured to rotate about a respective drum axis between a closed position and an open position. In the closed position, the forward portion and aft portion are positioned to block fluid communication between the forward axial passageway and the aft axial passageway. In the open position, the forward portion and aft portion are positioned to allow fluid communication between the forward axial passageway and the aft axial passageway.
The control unit is configured to rotate the plurality of drums about the respective drum axis between the closed position and the open position in response to preselected operating conditions to minimize negative effects pressure and swirl distortions in the gas turbine engine to improve stall margin.
In some embodiments, a respective bell crank is disposed near a forward end and an aft end of each one of the plurality of drums. The bell crank at the forward end is mechanically coupled with the forward portion. The bell crank at the aft end is mechanically coupled to the aft portion.
In some embodiments, a respective pinion is disposed near a forward end and an aft end of each one of the plurality of drums. The pinion at the forward end is engaged with a rack disposed on the forward portion. The pinion at the aft end is engaged with a rack disposed on the aft portion.
In some embodiments, a respective gear is disposed near a forward end and an aft end of each one of the plurality of drums. The gear at the forward end is engaged with the forward portion. The gear at the aft end is engaged with the aft portion. A respective motor is coupled to each one of the gears.
In some embodiments, a respective motor is disposed at a forward end and an aft end of each one of the plurality of drums. The motor at the forward end is configured to rotate the forward portion. The motor at the aft end is configured to rotate the aft portion.
In some embodiments, the respective forward portion and the aft portion are independently controlled.
In some embodiments, a method comprises providing a fan case assembly adapted for use with a gas turbine engine. The fan case assembly includes a case and a plurality of drums. The case extends circumferentially at least partway about a central axis of the gas turbine engine and is formed to define an outer boundary of a gas path of the gas turbine engine. The case is formed to define a circumferential channel that extends at least partway about the central axis.
The plurality of drums are arranged in axial grooves intersecting the circumferential channel. Each drum of the plurality of drums include a forward portion and an aft portion rotatably connected to the forward portion. The forward portion and aft portion each shaped to form a respective axial passageway. Each drum of the plurality of drums is configured to rotate about a respective drum axis.
In some embodiments, the method includes locating the plurality of drums in a closed position in which the forward portion and aft portion are positioned to block fluid communication between the forward axial passageway and the aft axial passageway.
In some embodiments, the method includes rotating the plurality of drums to an open position in which the forward portion and aft portion are positioned to allow fluid communication between the forward axial passageway and the aft axial passageway.
These and other features of the present disclosure will become more apparent from the following description of the illustrative embodiments.
For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to a number of illustrative embodiments illustrated in the drawings and specific language will be used to describe the same.
A fan case assembly 10 is adapted for use in a gas turbine engine 110 as shown in
In some embodiments, the fan 112 includes a fan rotor 12 and a fan case assembly 10 as shown in
The fan case assembly 10 includes, among other components, a case 20 and an inlet distortion mitigation system 22 as shown in
In some embodiments, the case 20 is formed to define a circumferential channel 48 that extends at least partway about the central axis 11, as shown in
As shown in
The forward portion 26A and the aft portion 26B of each drum 26 of the plurality of drums 26 configured to rotate about a respective drum axis between a closed position and an open position. In the closed positon, shown in
The system 22 and fan case assembly 10 include a control unit 30. The control unit 30 is configured to rotate the plurality of drums 26 about the respective drum axis between the closed position and the open position in response to preselected operating conditions to minimize negative effects pressure and swirl distortions in the gas turbine engine to improve stall margin. The control unit 30 includes one or more sensor 66, controller 62, memory 64, and/or actuator 60 to rotate the drums 26.
As shown in
In the open position, as shown in
As shown in
In some embodiments, as shown in
In some embodiments, in the open position as shown in
In a bypass position, as shown in
The passageway 28 of the forward portion 26A of the drums 26 may be shaped as a groove 28A without portions that connect to a circumferential channel, as shown in
In some embodiments, as shown in
In some embodiments, as shown in
In some embodiments, as shown in
In some embodiments, as shown in
In some embodiments, a method includes providing a fan case assembly 10 adapted for use with a gas turbine engine 110. The fan case assembly including a case 20 that extends circumferentially at least partway about a central axis 11 of the gas turbine engine 110 and is formed to define an outer boundary of a gas path 25 of the gas turbine engine 110. The case formed to define a circumferential channel 48 that extends at least partway about the central axis.
A plurality of drums 26 are provided and arranged in axial grooves 36 intersecting the circumferential channel 48. Each drum of the plurality of drums 26 including a forward portion 26A and an aft portion 26B rotatably connected to the forward portion 26A. The forward portion 26A and aft portion 26B are each shaped to form a respective axial passageway 28A, 28B. Each drum 26 is configured to rotate about a respective drum axis.
In some embodiments, the method includes locating the plurality of drums 26 in a closed position in which the forward portion 26A and aft portion 26B are positioned to block fluid communication between the forward axial passageway 28A and the aft axial passageway 28B, as shown in
The control unit 30 is configured to rotate the plurality of drums 26 about the respective drum axis between the closed position, the open position, and/or the bypass position. The control unit 30 is configured to rotate the drums 26 between the open positon and the closed position in response to preselected operating conditions to minimize negative effects pressure and swirl distortions in the gas turbine engine 110 to improve stall margin. The control unit 30 is configured to rotate each of the plurality of drums 26 about the corresponding drum axis A between the different positions in response to preselected operating conditions to control tip treatment of the fan blades 14.
The control unit 30 is configured to rotate each of the drums 26 to control whether the passageways 28 in each drum 26 face toward or away from the gas path 25, thereby controlling whether the passageways 28 are in fluid communication with the gas path 25 and/or the channel 48 to recirculate air at the tips of the fan blades 14. The control unit 30 controls the application of the tip treatment to the fan blades 14 so as to minimize the negative effects of pressure and swirl distortions in the gas turbine engine 110 to improve stall margin for the gas turbine engine 110.
The control unit 30 is configured to rotate the drums 26 between the different positions in response to preselected operating conditions. The preselected operating conditions include a plurality of preprogrammed aircraft maneuvers stored on a memory 64 included in the control unit 30. The plurality of preprogrammed aircraft maneuvers include banks, turns, rolls, etc.
The control unit 30 is configured to detect a preprogrammed aircraft maneuver included in the plurality of preprogrammed aircraft maneuvers on the memory 64. Once the preprogrammed aircraft maneuver is detected, the control unit 30 directs each of the drums 26 to rotate to a corresponding position in response to detecting the preprogrammed aircraft maneuver.
For example, the plurality of drums 26 may normally be in the closed position during a cruise condition so that no additional stall margin is created, but performance is not compromised. The cruise condition included in the preselected operating conditions corresponds to when the aircraft is in the cruise portion of the flight cycle.
Then, when the control unit 30 detects a preprogrammed aircraft maneuver, i.e. banks, turns, rolls, the control unit 30 directs the drums 26 to rotate to the open position so that the passageways 28 face toward the gas path 25 and flow is permitted into the passageways 28 and/or channels 48. The passageways 28 allow for air to recirculate at the tips of the fan blades 14.
Conversely, when the control unit 30 detects the cruise condition after a preprogrammed aircraft maneuver, the control unit 30 may be configured to direct the drums 26 to rotate to the closed position. Therefore, once the aircraft maneuver is completed, the drums 26 rotate to the closed position to remove the opening created in the outer boundary of the gas path 25 by the passageways 28 so that performance is not compromised and the additional stall margin is removed during the cruise condition.
The control unit 30 is configured to direct some or all of the drums 26 to rotate from the closed position to the open position based on the detected preprogrammed aircraft maneuver. Depending on the preprogrammed aircraft maneuver, the control unit 30 may direct only certain drums 26 to move to the open position, while keeping others in the closed position.
The preselected operating conditions may further include a sensor input from at least one sensor 66 included in the control unit 30. The sensor 66 is configured to measure one of pressure, air speed, altitude, blade tip timing, blade rotational speed, attitude or aircraft orientation, and acceleration. In some embodiments, the control unit 30 includes a plurality of sensors 66 each configured to measure one of pressure, air speed, altitude, blade tip timing, blade rotational speed, attitude or aircraft orientation, and acceleration.
The control unit 30 is configured to receive a measurement from the at least one sensor 66 or sensors 66 and direct the drums 26 to rotate to a corresponding position in response to the measurement of the at least one sensor 66. The control unit 30 may be configured to rotate the drums 26 to be in the closed position when the measurements from the sensor 66 are within a predetermined threshold.
Then, when the measurement from the sensor 66 is outside of the predetermined threshold, the control unit 30 directs the drums 26 to rotate to the open position. Based on the difference of the measurement from the sensor 66 compared to the predetermined threshold, the control unit 30 may vary the position of the drums 26 to control whether tip treatment is applied to the fan blades 14 of the fan 112. The control unit 30 may rotate certain drums 26 located circumferentially about the fan 112 to apply tip treatment at different areas around the fan 112. For example, the control unit 30 may direct certain drums 26 to be in the open position to open the passageways 28 of the corresponding drums 26 to the gas path 25 to allow air recirculation at that circumferential location about the fan 112.
The control unit 30 is configured to direct some or all of the drums 26 to rotate from the closed position to the open position based on the measurement from the sensor 66. As shown in
In some embodiments, the control unit 30 may be configured to use a combination of the sensor measurements and the detected preprogrammed aircraft maneuver to control the position of the plurality of drums 26. For example, when the control unit 30 detects a preprogrammed aircraft maneuver and the measurement is outside of the predetermined threshold, the control unit 30 directs some or all of the drums 26 to rotate to the open position. The control unit 30 is configured to individual vary the angle of the passageways 28 of each of the drums 26.
In some embodiments, the control unit 30 is configured to use the measurements from the sensor 66 to anticipate the aircraft maneuver. The control unit 30 is configured to direct some or all of the plurality of drums 26 to move to the open position in response to the measurement from the sensor 66 even though no preprogrammed aircraft maneuver is detected.
Alternatively, there may be a delay in the measurements from the sensor 66. Therefore, the control unit 30 is also configured to direct some or all of the drums 26 to move to the open position when the one of the preprogrammed aircraft maneuvers is detected, even though the measurements from the sensor 66 are within the predetermined thresholds.
In some embodiments, the control unit 30 may detect one of the preprogrammed aircraft maneuvers, but the measurements from the sensors 66 are within the predetermined threshold. If so, the control unit 30 may direct some or all of the drums 26 to remain in the current position.
In some embodiments, the inlet distortion mitigation system 22 may utilize a machine learning algorithm. The machine learning algorithm may track inputs, for example, aircraft speed, orientation, altitude, and/or fan speed versus a fan response, as well positioning of the drums 26, and learn how to move the inlet distortion mitigation system 22 to minimize stall margin loss. The mitigation system 22 may utilize the machine learning algorithm to gather data collected from the sensors 66 and/or other systems integrated with the engine 110 and evaluate the data, for example, to learn the correlation between certain environmental factors and/or inputs and stall margin. The algorithm may determine and learn how to minimize stall margin loss based on evaluation of the data collected, and be used by the system 22 to anticipate unfavorable conditions and better control the drums 26 to mitigate stall margin loss.
Embedded and boundary layer ingestion (BLI) applications may introduce severe distortion in the form of pressure gradients and swirl. A fan, for example, a fan of a gas turbine engine, must survive going through different sectors of their circumference with varying level of pressure or swirl magnitudes, which may be difficult to manage for stall or aeromechanical behavior. Flow distortions induced by different crosswind and flight orientation profiles may generate different flow distortions radially and circumferentially.
In some embodiments, the drums 26 are incorporated with a variable rotating array of drums 26 that may be rotated, as a whole or in smaller groupings, or turned individually to expose the fan tips to the grooves 36 and/or channel 48 via the drums 26. In some embodiments, the drums 26 connect circumferentially to channels 48, making the design relatively more compact and thus can fit in a small airframe better. The drum 26 changes between closed, transferring between flowpath 25 and channel 48, and transferring only between the channels 48 to either side of the drum 26 (not open to flowpath). This may allow for targeted transfer of flows from where there is excess flow and/or pressure to reduced flow and/or pressure. There may remain trades between efficiency and stall margin but in a more compact package potentially.
In some embodiments, the rotating drums 26 are incorporated into the fan case 20 or into liners and may be operated via a variable geometry system similar to variable vanes. It may be easiest to have the variable geometry system perpendicular to the drum 26 rotation axis, but it would also be possible to lay the drums in at an angle and actuate via small bevel gears at the drum 26 ends or similar. This may help offset the flows in the case 20.
In some embodiments, the drums 26 and system 22 permits the fan 112 to operate with the drums 26 limited to retain some efficiency, but then open to the channel 48 when stall margin improvement is desired. The passageways 28 may be located as necessary to treat forward or aft sections of the case 20. The passageways 28 may be be shaped to promote desired flow in both conditions.
In some embodiments, as the aircraft maneuvers and inlet flow distortion variations are generated, the drum 26 array may be rotated to provide either improved stall margin or closed to channels 48 to provide best efficiency. This may be beneficial to eliminate a troublesome trade between stall margin and performance potentially, or the system would be able to handle more extreme inlet distortion during maneuvering. In some embodiments, the channels 48 between drums 26 include options to go circumferential or axial and circumferential, the system 22 could be used for a tip injection like flow or a hoop plenum type flow solution.
In some embodiments, the system 22 design trades treated area for radial space, for example, by having fewer openings to the flowpath 25 but also being capable to be radially shorter than the design with a plenum outboard of the drums 26. It takes time for stall to develop so this may be acceptable trade. The drums 26 may be open to flowpath 25 and turn the flow to be tangential and flow in a passageway 28 or channel 48 within the liner/casing 20 space, and then would be turned again to be transferred back into the flowpath 25, as seen in
In some embodiments, it may be possible to include an additional pathway in the drum to permit pass-through without it being open to flowpath 25, which would allow for flows to bypass an opening and transfer to another circumferential location, as seen in
In some embodiments, while a radially outboard plenum may allow for transfers into and out of it by turning of the drums and relies on self-regulation of the flows (high pressure areas flow in, low pressure areas see flows from it), the design as seen in
The drum 26 design provides a way to control the flows as needed, as well as provide opportunity to integrate into a tip injection layout. One of the challenges of active tip injection is how to extract flows but also be able to turn it off as desired. The drums 26 design provides a means to control tip injection flows largely within the fan case liners by turning the drums
In some embodiments, the two drum portions 26A, 26B (divided axially) are connected so that flows may transfer between them. The drums portions 26A, 26B may rotate independently to communicate flow tangentially at one axial location between neighboring drums and then also transfer axially, then tangentially and axially to another drum. Alternatively, the flow may be shared tangentially fully at one axial location and then the drum 26 aligned appropriately forward and aft to flow axially. In some embodiments, the drums 26 may be driven or rotated by different means, which may include but not limited to stepper motors at the ends, bell crank, rack and pinion, gears through the case. It may be less than 180 degree coverage for some options.
Depending on system needs, the offset may be an extent of challenging distortion or the length it takes for stall to fully develop between areas. The drum 26 would turn to open from areas of higher pressure and treat areas forward of it with lower pressure or flow. While the drums 26 may be able to transfer flows axially forward within themselves, having channels 48 within the liner or casing traveling axially and circumferentially may be beneficial. If an area's aft portion has high pressure then its forward portion may also be high (even accounting for swirling flow). Therefore, there may also need to be circumferential relocation of the transfer flows.
Embodiments of the present disclosure were made with government support under Contract No. FA8650-19-D-2063 or FA8650-19-F-2078. The government may have certain rights.
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