Patent Application
20210016888
The subject matter disclosed herein generally relates to rotating machinery and, more particularly, to a method and an apparatus for modulated combustor bypass air flow for idle operation control in a hybrid propulsion system.
A hybrid propulsion system for an aircraft can include a gas turbine engine and at least one motor that supplements performance of the gas turbine engine. Gas turbine engines and motors typically have separate control laws to manage gas turbine power and electric power. Separate control laws can increase challenges in effectively managing events, such as rapid transients, thermal-mechanical stress, component lifespan, and/or other control goals. Even an engine idle condition supplemented by a motor in a hybrid propulsion system can impact efficiency of fuel consumption in a gas turbine engine. For example, adding power to a spool of a gas turbine engine using a motor can be limited by lean blow-out of the combustor of the gas turbine engine as fuel-air ratio is driven down by the motor.
According to one embodiment, a hybrid propulsion system includes a gas turbine engine having a low speed spool, a high speed spool, and a combustor. The low speed spool can include a low pressure compressor in a compressor section and a low pressure turbine in a turbine section, and the high speed spool can include a high pressure compressor in the compressor section and a high pressure turbine in the turbine section. The hybrid propulsion system also includes a motor configured to augment rotational power of the high speed spool, a flow modulation device configured to control a combustor bypass air flow around the combustor to the turbine section, and a controller. The controller is operable to determine a mode of operation of the gas turbine engine, apply supplemental power to the high speed spool using the motor, modulate the combustor bypass air flow using the flow modulation device based on determining that the gas turbine engine is in an idle mode of operation and supplemental power is applied to the high speed spool, and adjust a fuel-air ratio at the combustor based on modulation of the combustor bypass air flow and the supplemental power applied to the high speed spool.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include where the flow modulation device is configured to receive the combustor bypass air flow from the compressor section.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include where the flow modulation device is configured to receive the combustor bypass air flow from between the low pressure compressor and the high pressure compressor.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include where the flow modulation device is configured to receive the combustor bypass air flow from a bleed location between the compressor section and the combustor.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include where the combustor bypass air flow includes air compressed by a compression source external to the gas turbine engine.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include where the combustor bypass air flow is output to the high pressure turbine.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include a generator driven by the low speed spool, where the generator is configured to provide power to the motor.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include where the controller is configured to determine which available source of energy to draw from to provide supplemental power and power the motor by one or more of: a generator, an energy storage system, and a power source external to the gas turbine engine.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include where the controller is further configured to modulate the flow modulation device based on a cross-sectional area or a pressure ratio.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include where the controller is further configured to modulate the combustor bypass air flow as an engine cooling flow using the flow modulation device based on determining that the gas turbine engine is in a high engine power mode of operation above the idle mode of operation.
According to an embodiment, a method for controlling a hybrid propulsion system includes determining, by a controller, a mode of operation of a gas turbine engine having a low speed spool and a high speed spool. Supplemental power is applied to the high speed spool. The controller modulates a combustor bypass air flow around a combustor to a turbine section of the gas turbine engine using a flow modulation device based on determining that the gas turbine engine is in an idle mode of operation and supplemental power is applied to the high speed spool. The controller adjusts a fuel-air ratio at the combustor based on modulation of the combustor bypass air flow and the supplemental power applied to the high speed spool.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include driving a generator by the low speed spool and providing power produced by the generator to the motor.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include determining which available source of energy to draw from to provide supplemental power and powering the motor by one or more of: a generator, an energy storage system, and a power source external to the gas turbine engine.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include modulating the flow modulation device based on a cross-sectional area or a pressure ratio.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include modulating the combustor bypass air flow as an engine cooling flow using the flow modulation device based on determining that the gas turbine engine is in a high engine power mode of operation above the idle mode of operation.
In addition to one or more of the features described above or below, or as an alternative, further embodiments may include reducing a fuel flow to the combustor while modulating the combustor bypass air flow and applying supplemental power to the high speed spool to maintain a fuel-air ratio.
A technical effect of the apparatus, systems and methods is achieved by providing modulated combustor bypass air flow for idle operation control in a hybrid propulsion system.
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
The exemplary engine 20 generally includes a low speed spool 30 and a high speed spool 32 mounted for rotation about an engine central longitudinal axis A relative to an engine static structure 36 via several bearing systems 38. It should be understood that various bearing systems 38 at various locations may alternatively or additionally be provided, and the location of bearing systems 38 may be varied as appropriate to the application.
The low speed spool 30 generally includes an inner shaft 40 that interconnects a fan 42, a low pressure compressor 44 and a low pressure turbine 46. The inner shaft 40 is connected to the fan 42 through a speed change mechanism, which in exemplary gas turbine engine 20 is illustrated as a geared architecture 48 to drive the fan 42 at a lower speed than the low speed spool 30. The high speed spool 32 includes an outer shaft 50 that interconnects a high pressure compressor 52 and high pressure turbine 54. A combustor 56 is arranged in exemplary gas turbine 20 between the high pressure compressor 52 and the high pressure turbine 54. An engine static structure 36 is arranged generally between the high pressure turbine 54 and the low pressure turbine 46. The engine static structure 36 further supports bearing systems 38 in the turbine section 28. The inner shaft 40 and the outer shaft 50 are concentric and rotate via bearing systems 38 about the engine central longitudinal axis A which is collinear with their longitudinal axes.
The core airflow is compressed by the low pressure compressor 44 then the high pressure compressor 52, mixed and burned with fuel in the combustor 56, then expanded over the high pressure turbine 54 and low pressure turbine 46. The turbines 46, 54 rotationally drive the respective low speed spool 30 and high speed spool 32 in response to the expansion. It will be appreciated that each of the positions of the fan section 22, compressor section 24, combustor section 26, turbine section 28, and fan drive gear system 48 may be varied. For example, gear system 48 may be located aft of combustor section 26 or even aft of turbine section 28, and fan section 22 may be positioned forward or aft of the location of gear system 48.
The engine 20 in one example is a high-bypass geared aircraft engine. In a further example, the engine 20 bypass ratio is greater than about six (6), with an example embodiment being greater than about ten (10), the geared architecture 48 is an epicyclic gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3 and the low pressure turbine 46 has a pressure ratio that is greater than about five. In one disclosed embodiment, the engine 20 bypass ratio is greater than about ten (10:1), the fan diameter is significantly larger than that of the low pressure compressor 44, and the low pressure turbine 46 has a pressure ratio that is greater than about five 5:1. Low pressure turbine 46 pressure ratio is pressure measured prior to inlet of low pressure turbine 46 as related to the pressure at the outlet of the low pressure turbine 46 prior to an exhaust nozzle. The geared architecture 48 may be an epicycle gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3:1. It should be understood, however, that the above parameters are only exemplary of one embodiment of a geared architecture engine and that the present disclosure is applicable to other gas turbine engines including direct drive turbofans.
A significant amount of thrust is provided by the bypass flow B due to the high bypass ratio. The fan section 22 of the engine 20 is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet (10,688 meters). The flight condition of 0.8 Mach and 35,000 ft (10,688 meters), with the engine at its best fuel consumption—also known as “bucket cruise Thrust Specific Fuel Consumption (‘TSFC’)”—is the industry standard parameter of lbm of fuel being burned divided by lbf of thrust the engine produces at that minimum point. “Low fan pressure ratio” is the pressure ratio across the fan blade alone, without a Fan Exit Guide Vane (“FEGV”) system. The low fan pressure ratio as disclosed herein according to one non-limiting embodiment is less than about 1.45. “Low corrected fan tip speed” is the actual fan tip speed in ft/sec divided by an industry standard temperature correction of [(Tram ° R)/(518.7° R)]{circumflex over ( )}0.5. The “Low corrected fan tip speed” as disclosed herein according to one non-limiting embodiment is less than about 1150 ft/second (350.5 m/sec).
While the example of
In the example of
The electrical power system 210 can also include motor drive electronics 214A, 214B operable to condition current to the electric motors 212A, 212B (e.g., DC-to-AC converters). The electrical power system 210 can also include rectifier electronics 215A, 215B operable to condition current from the electric generators 213A, 213B (e.g., AC-to-DC converters). The motor drive electronics 214A, 214B and rectifier electronics 215A, 215B can interface with an energy storage management system 216 that further interfaces with an energy storage system 218. The energy storage management system 216 can be a bi-directional DC-DC converter that regulates voltages between energy storage system 218 and electronics 214A, 214B, 215A, 215B. The energy storage system 218 can include one or more energy storage devices, such as a battery, a super capacitor, an ultra capacitor, and the like. The energy storage management system 216 can facilitate various power transfers within the hybrid electric propulsion system 100. For example, power from the first electric generator 213A can be transferred 211 to the second electric motor 212B as a low speed spool 30 to high speed spool 32 power transfer. Other examples of power transfers may include a power transfer from the second electric generator 213B to the first electric motor 212A as a high speed spool 32 to low speed spool 30 power transfer. The energy storage management system 216 may also transfer power to one or more electric motors on the engine, or to external loads 217 and receive power from one or more external power sources 219 (e.g., aircraft power, auxiliary power unit power, cross-engine power, and the like).
A power conditioning unit 220 and/or other components can be powered by the energy storage system 218. The power conditioning unit 220 can distribute electric power to support actuation and other functions of the gas turbine engine 120. For example, the power conditioning unit 220 can power an integrated fuel control unit 222 to control fuel flow to the gas turbine engine 120. The power conditioning unit 220 can also power a plurality of actuators (not depicted), such as bleed actuators, vane actuators, and the like. A combustor bypass 224 can include a flow modulation device 226 that is configured to control a combustor bypass air flow around the combustor 56 (
The processing system 260 can include any type or combination of central processing unit (CPU), including one or more of: a microprocessor, a digital signal processor (DSP), a microcontroller, an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or the like. The memory system 262 can store data and instructions that are executed by the processing system 260. In embodiments, the memory system 262 may include random access memory (RAM), read only memory (ROM), or other electronic, optical, magnetic, or any other computer readable medium onto which is stored data and algorithms in a non-transitory form. The input/output interface 264 is configured to collect sensor data from the one or more system sensors and interface with various components and subsystems, such as components of the motor drive electronics 214A, 214B, rectifier electronics 215A, 215B, energy storage management system 216, integrated fuel control unit 222, combustor bypass 224, and/or other components (not depicted) of the hybrid electric propulsion system 100. The controller 256 provides a means for controlling the hybrid electric system control effectors 240 using a combustor bypass control 266 that is dynamically updated during operation of the hybrid electric propulsion system 100. The means for controlling the hybrid electric system control effectors 240 can be otherwise subdivided, distributed, or combined with other control elements.
The controller 256 with combustor bypass control 266 can apply control laws and access/update models to determine how to control and transfer power to and from the hybrid electric system control effectors 240. For example, sensed and/or derived parameters related to speed, flow rate, pressure ratios, temperature, thrust, and the like can be used to establish operational schedules and transition limits to maintain efficient operation of the gas turbine engine 120. For instance, a mode of operation of the gas turbine engine 120, such as idle, takeoff, climb, cruise, and descent can have different power settings, thrust requirements, flow requirements, and temperature effects. The combustor bypass control 266 can control the flow modulation device 226 to control a combustor bypass air flow 230 between a compression source 232 and an output 234. The compression source 232 can be internal to the gas turbine engine 120 (e.g., where source location 228 is proximate to compressor section 24) or external (e.g., a compressed air flow of an auxiliary power unit or other compressor). As the controller 256 adds rotational power to the high speed spool 32 using a motor, such as the second electric motor 212B, a fuel-air ratio at the combustor 56 can change. As fuel-air ratio is reduced during idle with power added to the high speed spool 32 by an electric motor 212B, a limiting factor can be lean blow-out of the combustor 56, where fuel can no longer be combusted. As the combustor bypass control 266 modulates (opens and closes) the flow modulation device 226, the combustor bypass air flow 230 can adjust the fuel-air ratio at the combustor 56. At low engine power levels, such as idle, the flow modulation device 226 can be controlled to increase the combustor bypass air flow 230 in order to decrease the flow going through the combustor 56 in order to raise fuel air ratio and prevent lean blow-out of the combustor 56. If the bypass bleed is also configured to cool the turbine, it may also be modulated up when increased cooling is required, such as at a high engine power mode of operation (e.g., takeoff and climb). Thus, the combustor bypass 224 can have multiple uses that shift depending upon the mode of operation of the gas turbine engine 120 and whether power is being added to the high speed spool 32 by a motor, such as the second electric motor 212B.
Referring now to
Referring now to
Referring now to
Method 600 pertains to the controller 256 executing embedded code for the combustor bypass control 266 to modulate combustor bypass air flow for idle operation control in a hybrid propulsion system. At block 602, the controller 256 can determine a mode of operation of a gas turbine engine 120 that includes a low speed spool 30 and a high speed spool 32. The mode of operation can be determined based on a thrust command, operating parameters, sensed values, and/or other factors known in the art. At block 603, the controller 256 can determine which available source of energy to draw from to provide supplemental power. For example, an available source of energy can be power from the first electric generator 213A, the energy storage system 218, one or more external power sources 219, or the like. Using the first electric generator 213A can have an effect on operating performance of the gas turbine engine 120. Stored energy availability or scheduled/reserved use may limit when energy is available from the energy storage system 218. Availability of one or more external power sources 219 may be constrained by activity associated with other electrical loads or other factors.
At block 604, the controller 256 can apply supplemental power to the high speed spool 32, for instance, using the second electric motor 212B. The flow modulation device 226 can be configured to receive the combustor bypass air flow 230 from a compressor section 24 of the gas turbine engine 120. As an example, the flow modulation device 226 can be configured to receive the combustor bypass air flow 230 from between the low pressure compressor 44 and the high pressure compressor 52. Alternatively, the flow modulation device 226 can be configured to receive the combustor bypass air flow 230 from a bleed location between the compressor section 24 and the combustor 56 of the gas turbine engine 120. As a further alternative, the combustor bypass air flow 230 can be air compressed by a compression source 232 external to the gas turbine engine 120.
At block 606, the controller 256 can modulate a combustor bypass air flow 230 around a combustor 56 to a turbine section 28 of the gas turbine engine 120 using a flow modulation device 226 based on determining that the gas turbine engine 120 is in an idle mode of operation and supplemental power is applied to the high speed spool 32. The combustor bypass air flow 230 can be output 234 to the high pressure turbine 54, for example. The location at or within high pressure turbine 54 at which the combustor bypass air flow 230 enters can be established at design time depending on flow requirements and available space. As an example, bypass flow can enter before or after a first vane stage (e.g., a choke point) of the high pressure turbine 54.
At block 608, the controller 256 can adjust a fuel-air ratio at the combustor 56 based on modulation of the combustor bypass air flow 230 and the supplemental power applied to the high speed spool 32.
In embodiments, a generator, such as the first electric generator 213A, can be driven by the low speed spool 30, where the generator is configured to provide power to the motor, such as the second electric motor 212B. As a further alternative, the motor can be powered by one or more of: a generator, an energy storage system 218, and a power source external to the gas turbine engine 120 (one or more external power sources 219). The generator providing power to the motor can be connected to a different thermal engine than the gas turbine engine 120. The controller 256 can be configured to modulate the flow modulation device 226 based on a cross-sectional area or a pressure ratio, for example. The controller can also be configured to modulate the combustor bypass air flow 230 as an engine cooling flow using the flow modulation device 226 based on determining that the gas turbine engine 120 is in a high engine power mode of operation above the idle mode of operation. The flow modulation device 226 can be modulated using one or more valves based on a level of compression provided by the gas turbine engine 120 and a cooling threshold. For instance, as the level of compression increases, resulting heat can increase the need to use the flow modulation device 226 for cooling. A cooling threshold, such as a temperature-based value can also or alternatively be used to determine when and how the flow modulation device 226 should be modulated for cooling. The controller 256 can also enable reducing a fuel flow to the combustor 56 while modulating the combustor bypass air flow 230 and applying supplemental power to the high speed spool 32 to maintain a fuel-air ratio. Fuel flow control can be managed by the controller 256 through the integrated fuel control unit 222. Thus, a modulated flow that bypasses the combustor 56 can be capable of raising fuel-air ratio at a constant fuel flow or reducing fuel flow at a constant fuel-air ratio, enabling more power transfer to the high speed spool 32 and reducing thrust or fuel flow.
While the above description has described the flow process of
The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.
