Patent Grant
11136892
This application is the US National Stage of International Application No. PCT/EP2017/054734 filed Mar. 1, 2017, and claims the benefit thereof. The International Application claims the benefit of European Application No. EP16159107 filed Mar. 8, 2016. All of the applications are incorporated by reference herein in their entirety.
The present invention relates to a rotor blade for a gas turbine, comprising a blade airfoil which extends in a radial direction and which has a blade airfoil body having a peripheral wall with a pressure-side wall section and a suction-side wall section, having a plate-like crown base which is connected to the peripheral wall in the region of the blade tip, and having a rubbing edge which extends along the peripheral wall, wherein the peripheral wall and the crown base define a cavity in the blade airfoil body, the rubbing edge is aligned on the outside with the peripheral wall and projects radially above the crown base, and in the blade airfoil body there are formed cooling ducts which extend from the cavity to cooling fluid outlet openings provided in the rubbing edge.
In a gas turbine plant, thermal energy and/or flow energy of a hot gas generated by combustion of a fuel is converted into rotational energy, which is normally converted by means of a generator into electrical energy. For this purpose, the gas turbine plant has a flow duct in whose axial direction a turbine rotor is rotatably mounted. The latter comprises a plurality of wheel disks on whose radially outer end surfaces there is arranged in each case a plurality of rotor blades in the form of a blade ring. For this purpose, the rotor blades each have blade roots which are inserted into one or more receiving grooves, which are formed on the end surfaces of the wheel disks, and are fixed therein.
Formed on the top side of the blade roots are blade platforms, from whose outer sides, facing away from the wheel disk, blade airfoils project into the flow duct.
During the operation of the gas turbine plant, the hot gas flows through the flow duct, with the flowing hot gas acting on the rotor blades with a force which, owing to the shape of the blade airfoils, is converted into a torque which acts on the turbine rotor and which drives the turbine rotor in rotation.
The thermodynamic efficiency of gas turbine plants is greater the higher the hot gas temperature in the gas turbine plant is. However, the magnitude of the hot gas temperature is subject to limits owing to the thermal load capacity of the rotor blades. Accordingly, an objective is to provide rotor blades which, even in the case of high thermal loading, have a mechanical strength which is sufficient for the operation of the gas turbine plant. For this purpose, rotor blades are provided with elaborate coating systems. In order to further increase the maximum permissible hot gas temperature, rotor blades are cooled during the operation of the gas turbine plant. For this purpose, cavities and cooling ducts, through which a cooling fluid, normally air, flows, are formed in their interior. Common cooling methods are for example impingement cooling, in which the cooling fluid is conducted such that it impinges on the wall of the blade airfoil from the inside, or film cooling, in which the cooling fluid flows outwardly from the interior of the blade airfoil through cooling bores, formed in the blade airfoil body, in order to form a cooling film on the outer side of said airfoil.
It is thus known for example from U.S. Pat. No. 5,733,102 and US 2014/044557 A1 to produce the blade airfoils of cooled rotor blades in a casting process. Common cast blade airfoils each comprise a hollow blade airfoil body which is closed off in the region of the blade tip by a so-called crown base. In the region of the blade tip, the blade airfoil body also bears a rubbing edge which is molded on the outside onto the blade airfoil body in a flush manner and projects in the radial direction along the outer contour of the peripheral wall of the blade airfoil body. A narrow radial gap of predefined width remains between the rubbing edge and a duct wall, which delimits the flow duct of the gas turbine plant, in order to allow low-friction rotation of the turbine rotor in the flow duct, on the one hand, but only to allow a small part of the hot gas to flow unused through the radial gap, on the other hand. In order to protect the rubbing edge, it is known to form cooling ducts in the rubbing edge for the purpose of cooling, which ducts extend from the cavity to cooling fluid outlet openings which are formed in the end surfaces of the rubbing edge.
After a specific operating duration of the turbine plant, changes in the radial gap can occur. For example, the turbine rotor can depart from its original central position due to creep, the length of the rotor blades can increase as a result of the centrifugal force, or a flow duct which is originally circular can become oval. These effects result from setting and/or elongation as a result of thermal loading by the hot gas and/or rotation-induced centrifugal forces or the force of gravity. The contact between the end surfaces of the rubbing edges and the duct wall which is thereby brought about leads to friction-induced removal of material, in the form of metal dust or metal chips, from the rubbing edges. It is then possible for the cooling fluid outlet openings to be clogged with the removed blade airfoil material, as a result of which cooling of the rubbing edges is impaired or prevented. The insufficient cooling of the rubbing edges leads to greater wear and, consequently, to a shorter service life of the blade airfoils.
EP 2 378 076 A1 thus discloses the blade tip of a turbine rotor blade, which blade tip is widened to form a winglet. The winglet projects on both sides of the blade airfoil of the rotor blade and is provided with a relatively narrow slot at the radial outside. The walls of the slot are of stepped form in one section, such that cooling openings open in the step. The radially outwardly facing wing surface is provided with an abrasive material in order to remove an abradable material on the opposite ring segments during a run-in phase and thus to provide the smallest possible radial gap between the blade tip and the opposite hot gas wall. Owing to the provision of a supply to the slot, which is arranged in the blade tip along the blade profile, and to the film-cooling bores arranged in the step, it is possible for abraded material to be carried out by the cooling medium flowing along the slot.
Furthermore, it is known from EP 1 281 837 A1 that cooling bores extending through the blade tip partly also extend in the inwardly facing surfaces of rubbing edges. In this way, improved cooling of rubbing edges of turbine blades is intended to be achieved.
EP 2 863 015 A1 discloses a similar arrangement with a step on the inner surface of a rubbing edge.
Proceeding from said prior art, it is an object of the present invention to provide a rotor blade for a gas turbine of the type mentioned in the introduction, which blade has an alternative structure and allows reliable cooling of the rubbing edge.
In order to achieve said object, the present invention provides a rotor blade for a gas turbine of the type mentioned in the introduction, wherein, in the end surface of the rubbing edge, there is formed at least one depression into which at least some of the cooling ducts open such that the cooling fluid outlet openings are completely situated in a base region of the at least one depression.
The invention is based on the consideration of lowering, with respect to the radial direction, the cooling fluid outlet openings in relation to the end surface of the rubbing edge. This is brought about according to the invention in that at least one depression is formed in the end surface of the rubbing edge and at least some of the cooling outlet openings are arranged completely in a base region of the at least one depression. In this way, the cooling fluid outlet openings are at a distance from the contact region between the end surface of the rubbing edge and the duct wall, as a result of which clogging of the cooling fluid outlet openings with removed blade airfoil material is reduced or prevented. Consequently, the cooling performance is substantially maintained over the operating duration of the gas turbine plant, this being associated with a correspondingly long service life of the blade airfoils.
Furthermore, with respect to the radial direction, the base region of the at least one depression is arranged between the end surface of the rubbing edge and the outer surface of the crown base. Advantageously here, the base region is formed as a planar base surface which, in relation to the end surface, has a depth which lies in the range of 0.5 mm to 4.5 mm and advantageously in the range of 0.5 mm to 2.5 mm. Such a radial position of the base region has the effect that, firstly, the cooling fluid outlet openings are arranged in the immediate proximity of the free end region of the rubbing edge, as a result of which effective cooling of this region of the rubbing edge can be ensured. Secondly, the low depth of the base surface of the depression in relation to the end surface is sufficient to prevent material particles removed from the end surface from clogging the cooling fluid outlet openings, this being associated with uniform cooling performance.
In a known manner, with respect to the radial direction, the rubbing edge has, in relation to the outer surface of the crown base, an overall height which lies in the range of 1 mm to 10 mm, advantageously in the range of 1.5 mm to 6 mm, and is advantageously 3.5 mm. In rubbing edges with an overall height in this range, the depressions can be readily formed with a suitable depth.
Furthermore, in relation to the radial direction, an inner surface of the rubbing edge is outwardly inclined so as to form a first inclination angle, wherein the first inclination angle is measured in a plane which extends in the radial direction and which perpendicularly intersects the rubbing edge, lies in the range of 0° to 45° and is advantageously greater than 10° and/or less than 30°. As a result of the inclination of the inner surface of the rubbing edge, the rubbing edge widens in the direction of the crown base from the end surface. This improves the stability of the rubbing edge and additionally improves the heat transport between the rubbing edge and the crown base or the peripheral wall.
Moreover, the at least one depression extends as far as an inner side of the rubbing edge so as to form a stepped cross section, wherein in particular, a step corner of the cross section, advantageously the inner corner, is rounded. In this configuration, at least one depression is formed so as to be open toward the inner side. Such depressions may be easily produced already during the casting of the blade airfoil body or only retroactively for example by milling or erosion.
Also, each cooling duct is, in relation to a plane which is perpendicular to the radial direction, inclined in the direction of the leading edge of the rotor blade, or in the direction of the trailing edge of the rotor blade, so as to form a third and/or fourth inclination angle, wherein the third inclination angle in the direction of the trailing edge of the rotor blade and the fourth inclination angle in the direction of the leading edge of the rotor blade are each measured in a plane which perpendicularly intersects the measurement plane of the first inclination angle, lies in the range between 30° and 90°, more advantageously between 30° and 80°, and is in particular 45°. Cooling ducts having such an inclination in the direction of the leading edge or in the direction of the trailing edge have a longer length, as a result of which the convective cooling of the rubbing edge is able to improve. In particular, an arrangement of cooling ducts which is inclined with respect to the trailing edge results in the jets being conducted above the tips of the suction-side rubbing edge and, there, cooling the surface, where it is generally the hottest. Moreover, they are able to favorably influence the flow direction of the exiting cooling fluid. Cooling ducts of different inclination directions may penetrate one another or may cross without penetration.
Advantageously, in the region of the at least one depression, the end surface of the rubbing edge has a width which is less than the thickness of the peripheral wall of the blade airfoil body in the region of the at least one depression. In addition, in the region of the depression, the end surface of the rubbing edge may have a width which is less than the width of the base region of the at least one depression. In this way, only a relatively narrow outer region of the rubbing edge forms its radially outer end region.
Advantageously, in the region of the at least one depression, the end surface of the rubbing edge and the base region of the at least one depression have, in combination, a width which is approximately equal to the thickness of the peripheral wall of the blade airfoil body in the region of the at least one depression. Such rubbing edges essentially constitute an extension of the peripheral wall of the blade airfoil body above the crown base.
It is alternately possible for the depression in the end surface of the rubbing edge to be formed as a groove, with an outer end-surface section and an inner end-surface section being left in the process, wherein in particular, the inner corners of the depression are rounded.
In this case, in the region of the depression, the width of the outer end-surface section and the width of the inner end-surface section of the rubbing edge may each lie in the range of 0.5 mm to 5 mm and advantageously be at least 1 mm, wherein the ratio between the outer width and the inner width lies in the range between 0.7 mm and 1.3 mm, in particular 0.9 and 1.1, and is advantageously 1.
According to a further variant, in the region of the depression, the peripheral wall narrows in the direction of the crown base in favor of the cavity, wherein the thickness of the peripheral wall is reduced from an initial thickness to a narrowed thickness which is at least half as large as the initial thickness, and the narrowing occurs over a radial section of the peripheral wall, the height of which radial section is at least five times and at most ten times as large as the initial thickness. As a result of the reduced thickness of the peripheral wall immediately below the crown base, it is possible for the cooling ducts to be formed such that they extend closer to the outer side of the rubbing edge, this being associated with improved convective cooling of the rubbing edge.
In the at least one depression, the cooling fluid outlet openings are advantageously arranged mutually adjacently and spaced apart from one another, in particular in an equidistant manner and/or along a line. Cooling fluid outlet openings arranged in such a way are especially suited for cooling the rubbing edge along its peripheral extent. In principle, however, the cooling fluid outlet openings may be distributed in any desired manner.
In a rotor blade according to the invention, the at least one depression may be provided only in a section of the rubbing edge which projects from the suction-side wall section of the surrounding wall. In this way, the cooling of the section of the rubbing edge which projects from the suction-side wall section of the peripheral wall can be improved.
In one variant of the present invention, precisely one depression is provided. This leads to a particularly simple embodiment of a rotor blade according to the invention.
Alternatively, it is possible to provide a plurality of depressions which are arranged mutually adjacently in the peripheral direction, into each of which some of the cooling ducts open and which in particular each have at least one above-mentioned feature. Multiple depressions lead to a corresponding grouping of the cooling ducts.
According to one variant, each cooling duct extends rectilinearly and/or has a circular cross section with a diameter which lies in the range of 0.25 mm to 2 mm and is advantageously 0.6 mm.
Here, the cooling ducts may be widened in the region of the cooling fluid outlet openings, wherein the widenings in particular have the form of a cylinder whose height is at most five times as large as, advantageously as large as, the diameter of the cooling duct and/or whose diameter is at most three times as large as, advantageously twice as large as, the diameter of the cooling duct. Cooling fluid outlet openings widened in this way may act as a diffusor and correspondingly widen the exiting cooling fluid stream, with the result that a large region of the rubbing edge can be cooled in accordance with the principle of film cooling. As an alternative to the cylindrical form, the cooling fluid outlet openings may also be widened conically, semi-conically or in a fan-like manner.
Advantageously, the cooling ducts are formed as bores. Bores allow rectilinear cooling ducts with circular cross section to be easily introduced into a cast blade airfoil body.
Advantageously, in relation to the radial direction, the cooling ducts are inclined transversely with respect to the inner surface of the rubbing edge so as to form a second inclination angle, wherein in particular, the second inclination angles of the cooling ducts, which angles are each measured in a plane which extends in the radial direction and which perpendicularly intersects the rubbing edge, are equal or approximately equal to the first inclination angle of the inner surface of the rubbing edge. Cooling ducts having such an inclination conduct from the inside to the outer end region of the rubbing edge the cooling fluid exiting the cooling fluid outlet openings.
According to a further development, a transition region between an inner surface of the rubbing edge and the outer surface of the crown base is rounded. This improves the aerodynamic properties of the blade tip. Otherwise, the inner surface of the rubbing edge is, as viewed along the radial direction, largely rectilinear.
In a manner known per se, the blade airfoil body is produced by casting or in a generative process, in particular by means of 3D printing. Casting has proven to be a suitable production process in particular for cooled blade airfoils having a cavity in their interior. However, generative processes are also suitable for producing blade airfoil bodies.
Further advantages and features of the present invention will become clear on the basis of six embodiments of a rotor blade according to the invention with reference to the appended drawing, in which:
The blade airfoil body 2 furthermore comprises a rubbing edge 7. The rubbing edge 7 extends along the peripheral wall 3 and is aligned on the outside therewith. In this case, the rubbing edge 7 projects radially above the crown base 4 and, with respect to the radial direction R, has, in relation to the outer surface 4a of the crown base, an overall height h, which is measured perpendicular to the outer surface 4a of the crown base and is approximately 3 mm. According to the cross-sectional view, an inner surface 7a of the rubbing edge 7 is formed to be largely rectilinear and is inclined at a first inclination angle δ of approximately 25° in relation to the radial direction R, said angle being measured in a plane which extends in the radial direction (R) and which perpendicularly intersects the rubbing edge 7. A transition region 8 between the inner surface 7a of the rubbing edge 7 and the outer surface 4a of the crown base 4 is formed to be rounded.
In a section of the rubbing edge 7 projecting from the suction-side wall section of the peripheral wall 3, there is formed a depression 9 which extends as far as the inner side of the rubbing edge 7 so as to form a stepped cross section. In this case, the inner corner 10 of the stepped cross section is rounded. The base region 9a of the depression 9 is formed as a planar base surface and, with respect to the radial direction R, is arranged between the end surface 7b of the rubbing edge 7 and the outer surface 4a of the crown base 4. Here, the outer surface 4a of the crown base 4, the base surface 9a of the depression 9 and the end surface 7b of the rubbing edge 7 extend parallel to one another and perpendicular to the radial direction R. In this way, the depression 9 has, in relation to the end surface 7b, a depth h1, which is measured as the perpendicular distance between the base surface 9a and the end surface 7b and is approximately 1 mm. Correspondingly, the perpendicularly measured height h2 of the base surface of the depression 9 above the outer surface 4a of the crown base 4 is approximately 2 mm. It is also possible, however, for the base surface 9a of the depression 9 and the outer surface 4a of the crown base 4 to be inclined with respect to one another and/or with respect to the radial direction R, it then being necessary for the depth h1 or the height h2 to in each case be determined with respect to the inner corner 10.
In the region of the depression 9, the end surface 7b of the rubbing edge 7 has a width a1 which is less than the thickness d1 of the peripheral wall 3 of the blade airfoil body 2 in the region of the depression 9. Moreover, in the region of the depression 9, the width a1 of the end surface 7b of the rubbing edge 7 is less than the width b1 of the base region 9a of the depression 9. In combination, the end surface 7b of the rubbing edge 7 and the base region 9a of the depression 9 have a width a1+b1 which is approximately equal to the thickness d1 of the peripheral wall 3 of the blade airfoil body 2 in the region of the depression 9, the thickness d1 being measured as the perpendicular distance between the outer surface and the inner surface of the surrounding wall 3. As can be seen in
Cooling ducts 11, which extend from the cavity 6 to cooling fluid outlet openings 12 which are provided in the rubbing edge 7, are formed in the blade airfoil body 2. The cooling ducts 11 open into the depression 9 such that the cooling fluid outlet openings 12 are arranged completely in the base region 9a of the depression 9. In this case, the cooling fluid outlet openings 12 are arranged in the depression 9 mutually adjacently in an equidistant manner and along a line. Each cooling duct 11 is formed as a bore and extends rectilinearly. It has a circular cross section with a diameter which is approximately 0.6 mm. In relation to the radial direction R, each cooling duct 11 is inclined transversely with respect to the inner surface 7a of the rubbing edge 7, with the second inclination angles θ of the cooling ducts 11, which angles are each measured in a plane which extends in the radial direction R and which perpendicularly intersects the rubbing edge 7, being approximately equal to the first inclination angle δ of the inner surface 7a of the rubbing edge 7.
One advantage of the rotor blade according to the invention is that the cooling ducts 11 are not or are only slightly clogged by way of material removal from the end surface 7b of the rubbing edge 7. This ensures cooling of the rubbing edge 7 which is uniform during the operation of the gas turbine, and thus a long service life of the rotor blade. A further advantage of the rotor blade according to the invention is that the depression 9 and the cooling ducts 11 are able to be produced easily. Owing to the low depth of the depression 9, effective cooling of the rubbing edge 7 over its overall height h remains possible. Moreover, the cooling fluid flowing out of the cooling fluid outlet openings 12 is scarcely deflected on its short path to the outer step of the rubbing edge 7 during the operation of the gas turbine, this being associated with effective cooling of the blade tip 5.
Although the invention has been more specifically illustrated and described in detail by the preferred exemplary embodiment, the invention is not limited by the examples disclosed, and other variations can be derived therefrom by a person skilled in the art without departing from the scope of protection of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 16159107 | Mar 2016 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2017/054734 | 3/1/2017 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2017/153219 | 9/14/2017 | WO | A |
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| 20200386104 A1 | Dec 2020 | US |
