Patent Application
20180030987
The field of the disclosure relates generally to gas turbine engines and, more particularly, to a method and apparatus for active clearance control in gas turbine engines.
During operation, at least some known aircraft engine components generate heat, which affect their performance. Such components include, for example, but not limited to, a high pressure compressor, which includes a rotor disk, compressor blades coupled to the rotor disk, and a casing housing the high-pressure compressor, and the combustion of gases in the combustion chamber. Differential thermal expansion of the disk, compressor blades, and compressor casing change the clearance between the tips of the compressor blades and the inner surface of the compressor casing. Engine inefficiencies occur when the clearance between the compressor blade tips and the inner surface of the compressor casing is large, thereby facilitating decreased compressor pressure rise capability and decreased stability, eventually leading to higher fuel consumption.
In addition, some known active mechanical control methods use linkages and actuation to control the clearance between the compressor blade tips and the inner compressor casing. Segmented shrouds attached to a unison ring and actuators individually control the positioning of each shroud. The active mechanical control method has a quick response rate, but the additional equipment required for the active mechanical control method adds weight to the aircraft.
In one aspect, a clearance control system for a rotatable machine is provided. The rotatable machine includes a compressor and an inner annular casing circumscribing at least a portion of the compressor. The inner annular casing includes a radially outer surface, a vertically upper portion, and a vertically lower portion. The clearance control system includes a manifold system including at least one conduit extending circumferentially around the vertically lower portion of the inner annular casing. The clearance control system includes a header system including at least one header extending circumferentially around the vertically lower portion of the inner annular casing. The at least one header configured to receive a flow of cooling fluid from the at least one conduit. The at least one header configured to channel the flow of cooling fluid to the vertically lower portion of the radially outer surface of the inner annular casing. The header system does not include a header extending circumferentially around the radially outer surface of the vertically upper portion of the inner annular casing.
In another aspect, a method of controlling a clearance between a tip of a plurality of compressor blades and an inner annular casing is provided. The inner annular casing includes a radially outer surface including a vertically upper portion and a vertically lower portion. The method includes channeling at least one flow of cooling fluid to a manifold system disposed on the vertically lower portion of the radially outer surface of the inner annular casing. The method also includes channeling the at least one flow of cooling fluid from the manifold system to the header system disposed on the vertically lower portion of the radially outer surface of the inner annular casing. The method further includes channeling the at least one flow of cooling fluid from the header system to the vertically lower portion of the radially outer surface of the inner annular casing. The header system does not include a header extending circumferentially around the radially outer surface of the vertically upper portion of the inner annular casing.
In yet another aspect, a rotatable machine is provided. The rotatable machine includes a compressor including an inner annular casing. The inner annular casing includes a radially outer surface, a vertically upper portion, and a vertically lower portion. The clearance control system includes a manifold system including at least one conduit extending circumferentially around the vertically lower portion of the inner annular casing. The clearance control system includes a header system including at least one header extending circumferentially around the vertically lower portion of the inner annular casing. The at least one header configured to receive a flow of cooling fluid from the at least one conduit. The at least one header configured to channel the flow of cooling fluid to the vertically lower portion of the radially outer surface of the inner annular casing. The header system does not include a header extending circumferentially around the radially outer surface of the vertically upper portion of the inner annular casing.
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of the disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of the disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.
In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.
The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.
Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
As used herein, the terms “processor” and “computer”, and related terms, e.g., “processing device”, “computing device”, and “controller” are not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits, and these terms are used interchangeably herein. In the embodiments described herein, memory may include, but is not limited to, a computer-readable medium, such as a random access memory (RAM), and a computer-readable non-volatile medium, such as flash memory. Alternatively, a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be used. Also, in the embodiments described herein, additional input channels may be, but are not limited to, computer peripherals associated with an operator interface such as a mouse and a keyboard. Alternatively, other computer peripherals may also be used that may include, for example, but not be limited to, a scanner. Furthermore, in the exemplary embodiment, additional output channels may include, but not be limited to, an operator interface monitor.
As used herein, the term “non-transitory computer-readable media” is intended to be representative of any tangible computer-based device implemented in any method or technology for short-term and long-term storage of information, such as, computer-readable instructions, data structures, program modules and sub-modules, or other data in any device. Therefore, the methods described herein may be encoded as executable instructions embodied in a tangible, non-transitory, computer readable medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described herein. Moreover, as used herein, the term “non-transitory computer-readable media” includes all tangible, computer-readable media, including, without limitation, non-transitory computer storage devices, including, without limitation, volatile and nonvolatile media, and removable and non-removable media such as a firmware, physical and virtual storage, CD-ROMs, DVDs, and any other digital source such as a network or the Internet, as well as yet to be developed digital means, with the sole exception being a transitory, propagating signal.
Embodiments of the active clearance control system described herein control the clearance between the inner annular casing of, for example, a high pressure compressor in a rotatable machine, e.g. an aircraft engine, and high pressure compressor blade tips. The active clearance control system includes an air inlet, a manifold system, a controller, and a header system. The manifold system and the header system are located on the vertically lower portion of the high pressure compressor. The air inlet directs fan air from the bypass airflow passage to the manifold system. The manifold system directs air to the header system. An air valve and a controller control the volume of air directed to the manifold system. The header system directs air to the inner annular casing of the high pressure compressor by directing air to the vertically lower portion of the radially outer surface of the inner annular casing. Cooling the vertically lower portion inner annular casing of the high pressure compressor reduces thermal expansion of the lower part of the casing and decreases the clearance between the inner annular casing of a high pressure compressor in an aircraft engine and high pressure compressor blade tips. Cooling only the bottom part of the compressor casing permits to reduce the clearance on the lower part of the engine, which counteracts the increased clearance caused by the engine thrust (phenomenon known as engine backbone bending). Additionally, a separate active clearance control system may be added to the vertically upper portion of the radially outer surface of the inner annular casing to independently cool the vertically upper portion of the radially outer surface of the inner annular casing. Independently cooling the vertically upper and lower portions optimizes the cooling capability of the active clearance controls systems to reduce fuel consumption.
The active clearance control system described herein offers advantages over known methods of controlling clearances in aircraft engines. More specifically, delivering bypass airflow passage air directly to the vertically lower portion or vertically upper portion of the surface of the HP compressor reduces thermal expansion of the HP compressor casing. Additionally, delivering bypass airflow passage air directly to the vertically lower or upper portion of the surface of the HP compressor rather than using actuators and linkages reduces the weight of the rotatable machine. Additionally, cooling only the vertically lower or upper portion of the HP compressor, rather than cooling the entire circumference of the HP compressor, reduces the weight of the rotatable machine. Finally, independently cooling the vertically upper and lower portions optimizes the cooling capability of the active clearance controls systems to reduce fuel consumption.
Exemplary core turbine engine 116 depicted generally includes a substantially tubular outer casing 118 that defines an annular inlet 120. Outer casing 118 and an inner casing 119 encases, in serial flow relationship, a compressor section 123 including a booster or low pressure (LP) compressor 122 and a high pressure (HP) compressor 124; a combustion section 126; a turbine section including a high pressure (HP) turbine 128 and a low pressure (LP) turbine 130; and a jet exhaust nozzle section 132. The volume between outer casing 118 and inner casing 119 forms a plurality of cavities 121. A high pressure (HP) shaft or spool 134 drivingly connects HP turbine 128 to HP compressor 124. A low pressure (LP) shaft or spool 136 drivingly connects LP turbine 130 to LP compressor 122. Compressor section 123, combustion section 126, turbine section, and nozzle section 132 together define a core air flowpath 137. HP compressor includes a plurality of HP compressor blades 139 configured to increase the pressure of a flow of air.
As shown in
Also, in the exemplary embodiment, disk 142 is covered by rotatable front hub 148 aerodynamically contoured to promote an airflow through plurality of fan blades 140. Additionally, exemplary fan section 114 includes an annular fan casing or outer nacelle 150 that circumferentially surrounds fan 138 and/or at least a portion of core turbine engine 116. Nacelle 150 is configured to be supported relative to core turbine engine 116 by a plurality of circumferentially-spaced outlet guide vanes 152. A downstream section 154 of nacelle 150 extends over an outer portion of core turbine engine 116 so as to define a bypass airflow passage 156 therebetween.
Inner casing 119 includes a vertically upper portion 151 and a vertically lower portion 153. Vertically lower portion 153 refers to the side of core turbine engine 116 facing the ground when aircraft 10 has weight on wheels. Vertically upper portion 151 refers to the side of aircraft 10 opposite vertically lower portion 153. Vertically upper portion 151 is bolted to vertically lower portion 153. Typically, vertically upper portion 151 is bolted to vertically lower portion 153 at the 3 and 9 o'clock circumferential positions. This arrangement permits the compressor blades to be changed without removing the entire engine.
A shown in
During operation of turbofan engine 110, a volume of air 158 enters turbofan engine 110 through an associated inlet 160 of nacelle 150 and/or fan section 114. As volume of air 158 passes across fan blades 140, a first portion of air 158 as indicated by arrows 162 is directed or routed into bypass airflow passage 156 and a second portion of air 158 as indicated by arrow 164 is directed or routed into core air flowpath 137, or more specifically into LP compressor 122. The ratio between first portion of air 162 and second portion of air 164 is commonly known as a bypass ratio. The pressure of second portion of air 164 is then increased as it is routed through HP compressor 124 and into combustion section 126, where it is mixed with fuel and burned to provide combustion gases 166.
A portion of first portion of air 162 as indicated by arrows 159 is directed into air conduit 155. Air conduit 155 channels portion of air 159 to manifold system 161 which channels portion of air 159 to header system 163. Header system 163 channels portion of air 159 to radially outer surface 169 of inner casing 119. Portion of air 159 is cooler than radially outer surface 169 of inner casing 119 and reduces the temperature of radially outer surface 169 of inner casing 119. Reducing the temperature of radially outer surface 169 of inner casing 119 reduces thermal expansion of inner casing 119 and improves the efficiency of HP compressor 124.
Combustion gases 166 are routed through HP turbine 128 where a portion of thermal and/or kinetic energy from combustion gases 166 is extracted via sequential stages of HP turbine stator vanes 168 that are coupled to outer casing 118 and HP turbine rotor blades 170 that are coupled to HP shaft or spool 134, thus causing HP shaft or spool 134 to rotate, thereby supporting operation of HP compressor 124. Combustion gases 166 are then routed through LP turbine 130 where a second portion of thermal and kinetic energy is extracted from combustion gases 166 via sequential stages of LP turbine stator vanes 172 that are coupled to outer casing 118 and LP turbine rotor blades 174 that are coupled to LP shaft or spool 136, thus causing LP shaft or spool 136 to rotate, thereby supporting operation of LP compressor 122 and/or rotation of fan 138.
Combustion gases 166 are subsequently routed through jet exhaust nozzle section 132 of core turbine engine 116 to provide propulsive thrust. Simultaneously, the pressure of first portion of air 162 is substantially increased as first portion of air 162 is routed through bypass airflow passage 156 before it is exhausted from a fan nozzle exhaust section 176 of turbofan engine 110, also providing propulsive thrust. HP turbine 128, LP turbine 130, and jet exhaust nozzle section 132 at least partially define a hot gas path 178 for routing combustion gases 166 through core turbine engine 116.
Exemplary turbofan engine 110 depicted in
A portion of first portion of air 162 as indicated by arrows 159 is directed into core compartment cooling system 302. Core compartment cooling system 302 channels air to offtake 304. Offtake 304 channels portion of air 159 to manifold system 161 which channels portion of air 159 to header system 163. Header system 163 channels portion of air 159 to radially outer surface 169 of inner casing 119. Portion of air 159 is cooler than radially outer surface 169 of inner casing 119 and reduces the temperature of radially outer surface 169 of inner casing 119. Reducing the temperature of radially outer surface 169 of inner casing 119 reduces thermal expansion of inner casing 119 and improves the efficiency of HP compressor 124. Cooling only vertically lower portion 153 of HP compressor 124, rather than cooling the entire circumference of HP compressor 124, reduces the weight of gas turbine engine 110.
During operation, a portion of first portion of air 162 as indicated by arrows 159 is directed into air conduit 655. Air conduit 655 channels portion of air 159 to manifold system 661 which channels portion of air 159 to header system 663. Header system 663 channels portion of air 159 to radially outer surface 169 of inner casing 119. Portion of air 159 is cooler than radially outer surface 169 of inner casing 119 and reduces the temperature of radially outer surface 169 of inner casing 119. Reducing the temperature of radially outer surface 169 of inner casing 119 reduces thermal expansion of inner casing 119 and improves the efficiency of HP compressor 124.
Active clearance control system 157 and second active clearance control system 657 independently cool radially outer surface 169 of inner casing 119. Independently cooling the vertically upper and lower portions 151 and 153 optimizes the cooling capability of the active clearance controls systems 157 and 657 to reduce fuel consumption of gas turbine engine 110.
In the exemplary embodiment, active clearance control system 157 and second active clearance control system 657 direct air from bypass airflow passage 156 to radially outer surface 169 of inner casing 119. In another embodiment, active clearance control system 157 and second active clearance control system 657 direct compressor bleed air to radially outer surface 169 of inner casing 119.
In the exemplary embodiment, active clearance control system 157 and second active clearance control system 657 are controlled by control valves 171 and 671. In another embodiment, active clearance control system 157 and second active clearance control system 657 may be controlled by a mechanical device similar to a governor which detect the speed of gas turbine engine 110 and adjust the flow of air to radially outer surface 169 of inner casing 119 according to the detected speed.
The above-described active clearance control system provides an efficient method for controlling the blade clearance in a rotatable machine. Specifically, delivering bypass airflow passage air directly to the vertically lower portion of the surface of the HP compressor reduces thermal expansion of the HP compressor casing. Additionally, delivering bypass airflow passage air directly to the vertically lower portion of the surface of the HP compressor rather than using actuators and linkages reduces the weight of the rotatable machine. Additionally, cooling only the vertically lower portion of the HP compressor, rather than cooling the entire circumference of the HP compressor, reduces the weight of the rotatable machine. Finally, independently cooling the vertically upper and lower portions optimizes the cooling capability of the active clearance controls systems to reduce fuel consumption.
An exemplary technical effect of the methods, systems, and apparatus described herein includes at least one of: (a) decreasing the temperature on the inner annular casing of a rotatable machine; (b) decreasing the clearance between the HP compressor blade tips and the inner annular casing of a rotatable machine; (c) decreasing the weight of a rotatable machine; and (d) decreasing the weight of an aircraft.
Exemplary embodiments of the active clearance control system are described above in detail. The active clearance control system, and methods of operating such units and devices are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other systems for controlling clearances, and are not limited to practice with only the systems and methods as described herein. Rather, the exemplary embodiment may be implemented and utilized in connection with many other machinery applications that require clearance control.
Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
Some embodiments involve the use of one or more electronic or computing devices. Such devices typically include a processor, processing device, or controller, such as a general purpose central processing unit (CPU), a graphics processing unit (GPU), a microcontroller, a reduced instruction set computer (RISC) processor, an application specific integrated circuit (ASIC), a programmable logic circuit (PLC), a field programmable gate array (FPGA), a digital signal processing (DSP) device, and/or any other circuit or processing device capable of executing the functions described herein. The methods described herein may be encoded as executable instructions embodied in a computer readable medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processing device, cause the processing device to perform at least a portion of the methods described herein. The above examples are exemplary only, and thus are not intended to limit in any way the definition and/or meaning of the term processor and processing device.
This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
