Patent Application
20140099210
The subject matter disclosed herein relates to gas turbine engines and, more specifically, to a system for joining compressor rotors; turbine rotors; and sections of turbines and compressors.
Gas turbine systems combust a fuel-air mixture to create rotational energy that drives a load or creates thrust. A compressor uses a series of rotor disks to progressively compress air that then mixes with fuel. This fuel-air mixture combusts and flows through a turbine causing a series of turbine rotor disks to spin. The series of compressor and turbine rotor disks transmit torque between neighboring rotor disks as they spin. Current rotor disks designs may connect to each other in ways that complicate field maintenance and repair; and that are less effective in transmitting torque.
Certain embodiments commensurate in scope with the originally claimed invention are summarized below. These embodiments are not intended to limit the scope of the claimed invention, but rather these embodiments are intended only to provide a brief summary of possible forms of the invention. Indeed, the invention may encompass a variety of forms that may be similar to or different from the embodiments set forth below.
In a first embodiment, a system, including a first turbomachine rotor disk, a first annular protrusion with a first spline coupled to the first turbomachine rotor disk, a second turbomachine rotor disk, and a second annular protrusion with a second spline coupled to the second turbomachine rotor disk, wherein the first and second splines are coupled to one another.
In a second embodiment, a system including, a gas turbine engine including a first rotor disk, wherein the first rotor disk includes a first annular protrusion with a first spline, and a second rotor disk, wherein the second rotor disk includes a second annular protrusion with a second spline, wherein the first and second splines are coupled to one another.
In a third embodiment a rotor disk coupling kit including, a first turbomachine rotor disk with a first and second axial sides, a first annular protrusion with at least one spline coupled to the first turbomachine rotor disk on the first axial side and a second annular protrusion with at least one spline coupled to the first turbomachine rotor disk on the first axial side.
These and other features, aspects, and advantages of the present invention 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:
One or more specific embodiments of the present invention will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.
When introducing elements of various embodiments of the present invention, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
The present disclosure is generally directed towards gas turbine rotor disks and gas turbine sections that connect using splines. More specifically, the turbine rotor disks and compressor rotor disks connect to each other using annular protrusions on the rotor disks. The annular protrusions include splines that interlock with splines on other rotor disk protrusions. These connections advantageously make it easier to connect a series of rotor disks, improve torque transmission between rotor disks, and control thermally induced run out imbalance. In some embodiments, the rotor disks may include more than one annular protrusion to further improve torque transmission and reduce thermally induced run out imbalance. The annular protrusions may be concentric with the rotor disk or placed at distinct locations on the rotor disk. Furthermore, the protrusions may include a conical feature that enables centering and radial alignment, ensuring that the splines on the different rotor disks properly interlock. In some embodiments, the rotor disks may include a tool slot. The tool slot allows a tool to assist in separating rotor disks (e.g., rotor disks that have excessive corrosion or oxidization, etc.) in a field environment eliminating or reducing the need to ship the entire compressor or turbine to a distant shop in order to separate the rotor disks. In addition, the present disclosure discloses a modular compressor and turbine formed from multiple sections. These sections may connect using a spline connection. The modular design of the compressor and turbine may advantageously assist in shipping the compressors and turbines (e.g., shipping in portions), assembly in the field, and the replacement of broken and worn out parts (e.g., by replacing a section instead of the entire compressor or turbine).
In operation, air enters the turbine system 10 through the air intake 28 and may be pressurized in a series of compressor stages (e.g., rotor disks 32) in the compressor 26. As illustrated, there are three compressor stages (e.g., rotor disks 32), but other embodiment may include different numbers of compressor stages (e.g., rotor disks 32) (e.g., 1, 2, 3, 4, 5, 10, or more). The compressor stages (e.g., rotor disks 32) may connect to one another with splines that effectively align and transmit torque between the rotor disks. The compressed air may then mix with gas for combustion within combustor 16. For example, the fuel nozzles 12 may inject a fuel-air mixture into the combustor 16 in a suitable ratio for optimal combustion, emissions, fuel consumption, and power output. The combustion generates hot pressurized exhaust gases, which then drive one or more blades connected to one or more turbine rotor disks 22 within the turbine 18 that then rotate the rotor disks 32 in the compressor 26, and thus the load 30. Accordingly, the rotation of the turbine rotor disks 22 causes a rotation of the compressor stages or rotor disks 32 (e.g., compressor blades) that then draw in and pressurize the air received by the intake 26.
The rotor disk 52 similarly includes a front face 80, a rear face 82, cooling slot 84, and a tool slot 86. The front face 80 includes an annular outer diameter protrusion 88 and an annular inner diameter protrusion 90. The rear face includes an annular outer diameter protrusion 92 and an annular inner diameter protrusion 94. In other embodiments, the faces 80 and 82 may include different numbers of protrusions (e.g., 1, 2, 3, 4, 5, 6, 7, or more annular protrusions). The annular protrusions 88, 90, 92, and 94 include respective splines 55 (e.g., 96, 98, 100, and 102), each having a plurality of teeth 53. As illustrated, the rotor disks 50 and 52 connect to one another by moving the rotor disk 50 in axial direction 104 and the rotor disk 52 in axial direction 106. The axial movement of the rotor disks 50 and 52 brings the annular protrusions 64 and 66 of rotor disk 50 into contact with the annular protrusions 92 and 94 of rotor disk 52. More specifically, the annular protrusions 64 and 66 define a respective radius that is less than the radii of the protrusions 92 and 94. The differences in the radii allow the protrusions 64, 66, 92, and 94 to axially overlap, so that the splines 72 and 100 and the splines 74 and 102 interlock with one another creating a secure connection between the rotor disks 50 and 52.
In order to center and align the rotor disks 50 and 52, the annular protrusions 64 and 66 may advantageously include a tapered guide feature, such as a tapered annular surface or conical surface. In the present embodiment, the protrusions 64 and 66 include respective angled surfaces 108 and 110 (e.g., conical surfaces or tapered annular surface) that facilitate alignment and centering of the rotor disks 50 and 52. The angled surfaces 108 and 110 may contact and slide past the surfaces 112 and 114 on the protrusions 92 and 94, thus aligning and centering the protrusions 64 and 66 with the protrusions 92 and 94. The protrusions 64 and 66 continue sliding over the protrusions 92 and 94 until the angled surfaces 108 and 110 contact the angled surfaces 116 and 118 of the rear face 82 on rotor disk disk 52. Simultaneously, the protrusions 92 and 94 continue sliding past the protrusions 64 and 66 until surfaces 112 and 114 contact the surfaces 120 and 122 of the front face 56 on rotor disk 50. As illustrated, the angled surfaces 108 and 110 form angles 124 and 126. The angles 124 and 126 correspond to angles 128 and 130 on the rotor disk 52. These angles 124, 126, 128, and 130 may be approximately within 1-89, 5-45, 10-35, 15-25, 20-70, or 30-60 degrees. In other embodiments, the surfaces 112, 114, 120, and 122 may also be angled for radial centering (e.g., to align rotational axes with one another) and alignment of the protrusions 92 and 94. In still other embodiments, the protrusions 92 and 94 may radially align the rotor disks 50 and 52 by angling surfaces 112, 114, 120, and 122 instead of the protrusions 64 and 66.
As illustrated, the spline 55 equipped protrusions 54 are at different radii on the rotor disks 50 and 52, in order to overlap one another. However, the radii of the spline 55 equipped protrusions 54 may change in order to vary how the protrusions 54 overlap one another. In the present embodiment, the spline 55 equipped protrusions 92 and 94 are at smaller radii on the rotor disk 52 than the radii of the protrusions 64 and 66 on rotor disk 50. In other embodiments, the reverse may occur to position the spline 55 equipped protrusions 64 and 66 at smaller radii than the spline 55 equipped protrusions 92 and 94. In still other embodiments, the protrusions 64 may be at a larger radius than the protrusion 92, while the protrusion 66 is at a smaller radius than the protrusion 94.
As explained above, the rotor disks 50 and 52 may include the cooling passages 60 and 84. The cooling passages 60 and 84 advantageously move cooling air through the rotor disks 50 and 52 and into the protrusions 54, thereby cooling the protrusions 54 and reducing thermal expansion. The cooling passages 60 and 84 therefore advantageously reduce thermal expansion and the associated problem of thermally induced run out imbalance, thus improving torque transmission. In some embodiments, the protrusions 54 may include apertures that allow the cooling air to flow through the slots 60 and 84 and out of the protrusions 54, thus effectively circulating cooling air through the protrusions 54.
As illustrated, the two spline 55 equipped protrusions 92 and 94 are at different radii, e.g., an inner radius and an outer radius. The protrusion 92 is at radius 154, while the protrusion 94 is at radius 156. Depending on the embodiment, the radii 154 and 156 may change (i.e., decrease or increase). Moreover, the illustrated protrusions 92 and 94 include splines 100 and 102 that face inward. In other embodiments, the splines 100 and 102 may change orientation by facing radially inward or outward. For example, in some embodiments, the splines 100 and 102 may face radially outward from the protrusions 92 and 94. In other embodiments, splines 100 may face radially inward while the splines 102 face radially outward. In still other embodiments, splines 100 may face radially outward while the splines 102 face radially inward. Regardless of whether the protrusions 92 and 94 face radially outwards or inwards, the protrusions 92 and 94 and their splines 100 and 102 provide an effective way for joining other rotor members and transmitting torque between turbine rotor disks 22 and compressor rotor disks 32.
Technical effects of the invention include the ability to connect rotor disks in a turbomachine (e.g., a turbine or compressor) using protrusions with splines. The spline containing protrusions advantageously improve torque transmission, control of thermal run out imbalance, and enable field serviceability (i.e., connection and separation) of the rotor disks. Furthermore, the protrusions may include a conical feature for aligning and centering the rotor disks during connection, and a tool slot to assist in separating the rotor disks. A tool may therefore engage the tool slots and separate the rotor disks in the field for maintenance purposes (e.g., repair or replacement of rotor disks). Finally, the compressor and turbine may include multiple sections (e.g., modular spline equipped units with one or more turbomachinery stages). A turbine or compressor formed from multiple sections enables ease in shipping large compressors and turbines (i.e., by shipping them in smaller sections), assembly in the field, and the ability to replace broken and worn out parts by replacing the section instead of the entire compressor or turbine.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention 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.
