The present invention generally relates to impeller backface shrouds and more particularly relates to impeller backface shrouds for use in gas turbine engines having impellers.
A thrust bearing is a component in a gas turbine engine that is designed to support other components of the gas turbine engine and to brace such other components against the thrust that they generate. One engine sub-assembly that is supported by a thrust bearing is commonly referred to as the spool. The spool includes a shaft, a compressor that may include an impeller or axial stages, and a turbine. The compressor and the turbine are mounted to the shaft and rotate together with the shaft. The compressor and the turbine each generate thrust that acts on the spool. The compressor generates thrust on the spool that pushes the spool towards the front of the engine while the turbine generates thrust that pushes the spool towards the rear of the engine. These oppositely directed thrusts are rarely, if ever equal. Consequently a net or resultant thrust acting in either the forward or rearward direction will be exerted on the spool as a result of the differing magnitudes of these oppositely directed forces (hereinafter, the “spool thrust”). The thrust bearing supports and braces the spool against the spool thrust to inhibit the spool from being displaced from its mounted position within the gas turbine engine.
Computational models are available that enable engine designers to estimate the direction and magnitude of the spool thrust that will be generated by a spool when designing and developing new gas turbine engines. These estimates are then used to design thrust bearings that will be sufficiently robust to support and brace the spool against the anticipated spool thrust. However, the computational models are not exact and it is often the case that the direction and/or the magnitude of the spool thrust of the spool, once built, differs from what was predicted by such models.
If the difference between the anticipated spool thrust and the actual spool thrust differs substantially, then the thrust bearing will be required to brace the spool against significantly more or significantly less spool thrust than it was designed to accommodate. If too much spool thrust is exerted on the thrust bearing, in either the forward or rearward direction, the ball bearings in the thrust bearing can damage their housing. If excessive spool thrust is continued for any length of time, the thrust bearing may fail. If too little spool thrust is exerted on the thrust bearing, then there will be an insufficient amount of friction acting on the ball bearings in the thrust bearing, causing them to skip and skid. This, in turn, may also damage their housing and may also lead to failure of the thrust bearing.
When the actual spool thrust differs substantially from the anticipated spool thrust, the conventional solution has been to redesign the thrust bearings to accommodate the actual spool thrust. Although this solution is adequate, the amount of time needed to design, develop and manufacture new thrust bearings is quite substantial. Thus, this solution can delay engine development by months or years which, in turn, can cost the engine developer millions of dollars.
Although, the present invention describes an impeller backface shroud for use with a gas turbine engine having an impeller, the embodiment may also comprise the compressor disk-shroud spacing behind the last stage of an axial compressor as well. Gas turbine engines that employ such impeller or compressor disk backface shrouds, and methods of using such impeller or compressor disk backface shrouds are disclosed herein.
In an embodiment, the impeller backface shroud includes, but is not limited to a substantially funnel shaped body having a surface. The substantially funnel shaped body is configured to be statically mounted to the gas turbine engine in a position that is substantially coaxial with the impeller. The surface and a backface of the impeller forming a cavity that is configured to guide an airflow portion from the impeller to a turbine when the substantially funnel shaped body is mounted to the gas turbine engine coaxially with the impeller and axially spaced apart therefrom in an aft direction. A recessed groove is defined in the surface. The airflow portion has a tangential velocity and the recessed groove is oriented generally transversely to the tangential velocity of the airflow portion and is configured to at least partially interfere with the airflow portion, whereby a static pressure in the cavity is affected.
In another embodiment, the gas turbine engine includes, but is not limited to a shaft, an impeller affixed to the shaft, a turbine affixed to the shaft at a location aft of the impeller, and an impeller backface shroud. The impeller backface shroud includes, but is not limited to, a substantially funnel shaped body having a surface. The substantially funnel shaped body is statically mounted to the gas turbine engine in a position that is substantially coaxial with the impeller and axially spaced apart therefrom in an aft direction. The surface and a backface of the impeller form a cavity. The cavity is configured to guide an airflow portion from the impeller to the turbine. The airflow portion has a tangential velocity. A recessed groove is defined in the surface. The recessed groove is oriented generally transversely to the tangential velocity of the airflow portion and is configured to at least partially interfere with the airflow portion, whereby a static pressure in the cavity is affected.
In another embodiment, a method for compensating for an undesirable amount of spool thrust in a gas turbine engine is disclosed. The gas turbine engine has a shaft, an impeller affixed to the shaft, a turbine affixed to the shaft at a location aft of the impeller, and an impeller backface shroud statically mounted to the gas turbine engine in a position that is coaxial with the impeller and aft thereof such that a surface of the impeller backface shroud and a backface of the impeller form a cavity configured to guide an airflow portion from the impeller to the turbine. The airflow portion has a tangential velocity. The method includes, but is not limited to, the steps of (A) determining a target static pressure, (B) performing a computational fluid dynamic analysis using a processor to determine a static pressure in the cavity that would result from defining a recessed groove in the surface of the backface shroud, the recessed groove having a predetermined configuration, (C) changing the predetermined configuration of the recessed groove if the static pressure in the cavity differs substantially from a target static pressure, (D) repeating steps B and C until a predetermined configuration of the recessed groove that yields a static pressure in the cavity that does not differ substantially from the target static pressure is determined, (E) manufacturing a second impeller backface shroud including a recessed groove having the predetermined configuration determined at step D, and (F) assembling the second impeller backface shroud to the gas turbine engine.
The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and
The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.
Impeller 24 contributes to the movement of the airflow through gas turbine engine 20. Impeller 24 takes airflow that is moving in an axial direction and spins it rapidly, which together with the contour of impeller 24, changes the direction of the airflow's movement from axial to radial. Impeller 24 includes multiple impeller fins 30 extending longitudinally along an impeller surface 32 and which are oriented generally transversely to impeller surface 32. Impeller fins 30 are configured and contoured to receive the axially flowing airflow and to redirect it so that it flows in a radial direction.
An impeller shroud 34 is statically mounted (i.e., it does not rotate together with shaft 22) to an internal portion of gas turbine engine 20. Impeller shroud 34 is positioned in a closely spaced apart relationship with an outer periphery of impeller fins 30. This closely spaced apart relationship inhibits air from bleeding off of the periphery of impeller fins 30 as impeller 24 rotates. In this manner, impeller shroud 34 cooperates with impeller 24 to confine the airflow to a path bounded on one side by impeller surface 32 and bounded on the other side, by impeller shroud 34. While a gap is illustrated between impeller fins 30 and impeller shroud 34, it should be understood that the gap is exaggerated to assist the viewer in comprehending where impeller shroud 34 ends and where impeller fins 30 begin.
Conduits 36 are statically mounted to an internal portion of gas turbine engine 20 and are positioned to receive the airflow as it exits impeller 24. Conduits 36 convey the airflow from impeller 24 to turbine 28.
An impeller backface 38 is located at a rear portion of impeller 24 and rotates together with impeller 24. Impeller backface 38 extends radially inwardly from a periphery of impeller 24 towards shaft 22. Impeller backface 38 comprises a generally smooth surface having a gentle, curved contour that is substantially radially oriented at its axially forward end and that is substantially axially oriented at its axially rear end.
An impeller backface shroud 40 is statically mounted to an internal portion of gas turbine engine 20 and therefore does not rotate with shaft 22. Impeller backface shroud 40 may be mounted to gas turbine engine 20 by any suitable means including, but not limited to, the use of fasteners or welds. Impeller backface shroud 40 is a generally funnel shaped component that is axially spaced apart from impeller backface 38. Impeller backface 38 and impeller backface shroud 40 form a cavity 42. A gap 44 between the periphery of impeller 24 and conduits 36 permits a portion of the airflow to be redirected into cavity 42. This redirected portion of the airflow is used to cool turbine 28.
As airflow 46 continues to move through impeller 24, the curvature of impeller surface 32 causes airflow 46 to change directions from an axial flow to a radial flow. With respect to the illustrated embodiment, by the time that airflow 46 reaches impeller exit 50, it no longer has any significant axial velocity component. Rather, its movement is generally in the radial direction. Additionally, airflow 46 continues to spin (i.e., to have a tangential velocity) due to the spinning of impeller 24.
A portion of airflow 46 (hereinafter “airflow portion 52”) does not flow from impeller 24 into conduit 36. Rather, airflow portion 52 flows around a radial tip of impeller 24, through gap 44 and into cavity 42. Once airflow portion 52 enters cavity 42, it moves through cavity 42 and on to the turbine. Airflow portion 52 is used to cool the turbine and other portions of gas turbine engine 20.
Due to the contours of impeller backface 38 and impeller backface shroud 40, as airflow portion 52 moves through cavity 42, it must flow radially inward. However, when airflow portion 52 enters cavity 42, it still has a significant tangential velocity as it did while flowing through impeller 24. Therefore, airflow portion 52 has a tendency to move radially outward under the influence of the centrifugal force acting on airflow portion 52 by its rotation or tangential velocity. This tendency towards radially outward movement is overcome by the pressure differential that exists between the relatively high pressure air leaving impeller 24 and the relatively low pressure air contained within cavity 42. This pressure differential effectively draws the airflow portion 52 in a radially inward direction through cavity 42.
A portion of airflow 46′ (hereinafter “airflow portion 52′”) flows around a radial tip of axial compressor rotor 25, through gap 44′ and into a cavity 42′ formed by an axial compressor rotor backface 38′ and an axial compressor backface shroud 41. Once airflow portion 52′ enters cavity 42′, it moves through cavity 42′, and on to turbine 28′. Airflow portion 52′ is used to cool turbine 28′ and other portions of gas turbine engine 20′.
Due to the contours of axial compressor backface 38′ and impeller backface shroud 41, as airflow portion 52′ moves through cavity 42′, it must flow radially inward. However, when airflow portion 52′ enters cavity 42′, it still has a significant tangential velocity as it did while flowing through axial compressor rotor 25. Therefore, airflow portion 52′ has a tendency to move radially outward under the influence of the centrifugal force acting on airflow portion 52′ by its rotation or tangential velocity. This tendency towards radially outward movement is overcome by the pressure differential that exists between the relatively high pressure air leaving axial compressor rotor 25 and the relatively low pressure air contained within cavity 42′. This pressure differential effectively draws airflow portion 52′ in a radially inward direction through cavity 42′.
It is a well known principle, based on the Bernoulli equation, that the faster that air flows, the lower its static pressure will be. Conversely, the slower that air flows, the higher its static pressure will be. With continuing reference to
With continuing reference to
With continuing reference to
Each configuration disrupts airflow portion 52 to a different degree, each resulting in a different amount of reduction in the tangential velocity of airflow portion 52 and consequently increasing the static pressure within cavity 42 by a different amount. By varying the geometry of the impeller backface shroud, a designer may adjust the static pressure acting on the spool and thereby reduce or increase the spool thrust to a desired or target level. This capability obviates the need to redesign the thrust bearings. Impeller backface shrouds can be fabricated quickly and inexpensively and doing so would enable a designer to avoid the expense and delay associated with designing and fabricating new thrust bearings.
Although, the present invention describes an impeller backface shroud for use with a gas turbine engine having an impeller, it should be understood that the embodiment may also comprise the compressor disk-shroud spacing behind the last stage of an axial stage compressor disk as well.
At block 84, a computational fluid dynamic analysis, as is commonly employed by those of ordinary skill in the art, is performed to determine what static pressure in the cavity would result if a specific recessed groove configuration were to be employed. Such analysis is commonly performed using a computer running suitable software. One such commercially available software program is ANSYS Fluent. Other programs are also available in the market that could also be used when performing this analysis, such as ANSYS CFX or Numeca Fine/Turbo.
At block 86, the recessed groove configuration is changed if the analysis performed at block 84 does not yield a static pressure in the cavity that is sufficiently close to the target pressure.
At block 88, the steps performed at blocks 84 and 86 are repeated until a static pressure is calculated that is sufficiently close to the target pressure.
At block 90, a second impeller backface shroud having recessed grooves having the configuration determined at block 88 is fabricated.
At block 92, the impeller backface shroud fabricated at block 90 is assembled to the gas turbine engine.
While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims.
Number | Name | Date | Kind |
---|---|---|---|
3565543 | Mrazek | Feb 1971 | A |
6276896 | Burge et al. | Aug 2001 | B1 |
7008177 | Britt et al. | Mar 2006 | B2 |
7338251 | Ro et al. | Mar 2008 | B2 |
7775758 | Legare | Aug 2010 | B2 |
7909580 | Simpson et al. | Mar 2011 | B2 |
20080080969 | Legare et al. | Apr 2008 | A1 |
20080193277 | Legare | Aug 2008 | A1 |
Number | Date | Country | |
---|---|---|---|
20110299972 A1 | Dec 2011 | US |