The present invention generally relates to exhaust flow mixers, and more particularly relates to an exhaust flow mixer for a turbofan engine that improves performance and reduces noise.
A gas turbine engine may be used to power various types of vehicles and systems. A particular type of gas turbine engine that may be used to power aircraft is a turbofan gas turbine engine. A turbofan gas turbine engine may include, for example, a fan section, a compressor section, a combustor section, a turbine section, and an exhaust section. The fan section is positioned at the front, or “inlet” section of the engine, and includes a fan that induces air from the surrounding environment into the engine, and compresses a fraction of this air into the compressor section. The remaining fraction of air induced into the fan section is compressed into and through a bypass duct.
The compressor section further raises the pressure of the air it receives from the fan section to a relatively high level. In a multi-spool engine, the compressor section may include two or more compressors, such as, for example, a high pressure compressor and a low pressure compressor. The compressed air from the compressor section then enters the combustor section, where fuel nozzles inject a steady stream of fuel into a plenum formed by liner walls and a dome. The injected fuel is ignited in the combustor, which significantly increases the energy of the compressed air. The high-energy, compressed air from the combustor section then flows into and through the turbine section, causing rotationally mounted turbine blades to rotate and generate energy.
The air exhausted from the turbine section and the bypass air are directed into a mixer. In particular, the bypass air enters the cold side of the mixer and the exhaust air enters the hot side of the mixer. The bypass air and exhaust air exit are mixed upon exiting the mixer. This exhaust/bypass mixture is then discharged from the engine via an exhaust nozzle. Thrust is generated as the exhaust/bypass mixture expands through the exhaust nozzle.
Under ideal theoretical conditions a mixer combines the bypass air and the exhaust air to maximize exhaust jet momentum as the bypass/exhaust mixture expands through the exhaust nozzle. Doing so provides increased thrust and reduced thrust specific fuel consumption (TSFC). The physics that makes this possible is that momentum (exhaust jet thrust) is a linear function of the expanded jet velocity while the kinetic energy of the expanded jet is a function of velocity squared. Hence, it can be shown that a mixed flow stream can be expanded to produce more thrust than the sum of the individual unmixed streams. However, pressure losses associated with the mixing process reduce the available expanded jet velocity which in turn decreases the engine thrust and offsets some of the mixing benefit. Therefore, the challenge in designing an efficient mixer is to maximize the mixing efficiency while at the same time minimize the pressure loss associated with the mixing process.
Recently, many turbofan engines use what are referred to as multi-lobed mixers. Most multi-lobed mixers are constructed with lobes formed from straight sidewalls and circular arcs. Indeed, multi-lobed mixers with these types of mixer lobes has become an industry standard based on the conclusion that this type of lobe quickly mixes the bypass air and exhaust air. While this industry standard practice of manufacturing mixers with lobes formed from straight sidewalls, which are usually almost parallel, and circular arcs generally works well to maximize mixing efficiency, it does not address the goal of minimizing the associated pressure loss.
Accordingly, there is a need for an improved mixer design that maximizes the mixing efficiency and minimizes the associated pressure loss to significantly reduce the fuel consumption of a turbofan engine. The present invention addresses at least this need.
In one exemplary embodiment, a mixer nozzle for a turbofan engine includes a main body having a forward end, an aft end, a plurality of circumferentially spaced mixer lobes extending therefrom, and an inner surface that defines a flow passage between the forward end and the aft end. Each of the mixer lobes extends axially in a rearward direction toward the aft end and has a cross-section shape defined by a set of equations.
In another exemplary embodiment, a mixer for a turbofan engine includes a centerbody and a mixer nozzle. The centerbody is adapted to couple to a turbofan engine section. The mixer nozzle surrounds at least a portion of the centerbody and is spaced apart therefrom to define a core flow path between the mixer nozzle and the centerbody. The mixer nozzle is adapted to couple to the turbofan engine and includes a forward end, an aft end, and a plurality of circumferentially spaced mixer lobes. Each of the mixer lobes extends axially in a rearward direction toward the aft end. A portion of the mixer lobes extend radially inwardly, and a portion of the mixer lobes extend radially outwardly. The mixer nozzle is configured, when bypass air flows through the turbofan engine, to direct at least a portion of the bypass air to impinge on the centerbody.
In still another exemplary embodiment, a turbofan engine includes an engine nacelle, a gas turbine engine, a fan, and a mixer assembly. The engine nacelle has an inner surface. The gas turbine engine is mounted in the engine nacelle and is spaced apart from the nacelle inner surface to define a bypass flow passage between the engine nacelle inner surface and the gas turbine engine. The gas turbine engine is configured to rotate and supply a rotational drive force, and is further configured to receive a flow of air and fuel and to discharge exhaust gas. The fan is rotationally mounted within the engine nacelle and is coupled to receive the rotational drive force from the gas turbine engine. The fan is configured, upon receipt of the rotational drive force, to supply a flow of bypass air to the bypass flow passage and a flow of intake air to the gas turbine engine. The mixer assembly is mounted in the engine nacelle, and is coupled to receive and mix the bypass air and the exhaust gas. The mixer assembly includes a centerbody, and a mixer nozzle. The centerbody is coupled to the gas turbine engine. The mixer nozzle surrounds at least a portion of the centerbody and is spaced apart therefrom to define an exhaust flow path between the mixer nozzle and the centerbody. The mixer nozzle is coupled to the gas turbine engine and includes a forward end, an aft end, and a plurality of circumferentially spaced mixer lobes. Each of the mixer lobes extends axially in a rearward direction toward the aft end. A portion of the mixer lobes extend radially inwardly, and a portion of the mixer lobes extend radially outwardly. The mixer is configured to direct at least a portion of the bypass air to impinge on the centerbody.
Furthermore, other desirable features and characteristics of the mixer nozzle and mixer assembly will become apparent from the subsequent detailed description of the invention and the appended claims, taken in conjunction with the accompanying drawings and this background of the invention.
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.
Turning now to
The compressor section 104 may include one or more compressors 124, which raise the pressure of the air directed into it from the fan 114, and direct the compressed air into the combustion section 106. In the depicted embodiment, only a single compressor 124 is shown, though it will be appreciated that one or more additional compressors could be used. In the combustion section 106, which includes a combustor assembly 126, the compressed air is mixed with fuel supplied from a non-illustrated fuel source. The fuel and air mixture is combusted, and the high energy combusted fuel/air mixture is then directed into the turbine section 108.
The turbine section 108 includes one or more turbines. In the depicted embodiment, the turbine section 108 includes two turbines, a high pressure turbine 128, and a low pressure turbine 132. However, it will be appreciated that the engine 100 could be configured with more or less than this number of turbines. No matter the particular number, the combusted fuel/air mixture from the combustion section 106 expands through each turbine 128, 132, causing it to rotate. As the turbines 128 and 132 rotate, each drives equipment in the engine 100 via concentrically disposed shafts or spools. Specifically, the high pressure turbine 128 drives the compressor 124 via a high pressure spool 134, and the low pressure turbine 132 drives the fan 114 via a low pressure spool 136. The gas exhausted from the turbine section 108 is then directed into the exhaust section 112.
The exhaust section 112 includes a mixer 138 and an exhaust nozzle 142. The mixer 138 includes a centerbody 144 and a mixer nozzle 146, and is configured to mix the bypass air flow with the exhaust gas from the turbine section 108. The bypass air/exhaust gas mixture is then expanded through the propulsion nozzle 142, providing forward thrust. The mixer 138, an embodiment of which will now be described in more detail, provides increased mixing efficiency and lower pressure loss as compared to presently known mixers. As a result, the mixer 138 significantly reduces the specific fuel consumption of the turbofan engine 100.
Turning now to
The mixer nozzle 146 is adapted to couple to the engine cowl 122. The mixer nozzle 146, when coupled to the engine cowl 122, surrounds at least a portion of the centerbody 144 and is spaced apart therefrom to define an exhaust flow path 402 (see
The mixer nozzle 146 includes a forward end 202, an aft end 204, and a plurality of circumferentially spaced mixer lobes 206. It is seen most clearly in
No matter the specific number of mixer lobes 206 that are included, each is aerodynamically shaped to reduce drag, and thus minimize pressure losses in the mixer 138. The aerodynamic shape also minimizes the generation of axial vortices, or angular momentum, which further minimizes pressure losses during the mixing process. The aerodynamic shape of the mixer lobes 308 is provided by implementing each mixer lobe 308 to have a cross-section shape, from aft looking forward, that is defined by the following set of equations:
The variables in Equations (1)-(4) are defined below, and for added clarity are also depicted, as appropriate, in
It is noted that although the values of pc, pv, and pp may vary, preferably the value of pc is between 0 and 0.2, the value of pv is defined to obtain a desired flow area, and the value of pp is between 0 and 2.0. It is further noted that these values may be constant, or one or more of these values may be varied, within these ranges, along the axial position of the mixer nozzle 146 to optimize performance. In one particular preferred embodiment, the value of pp is about 0.4, and most preferably about 0.425. To clearly illustrate the effect of pp on mixer lobe 206 cross section shape, two mixer lobe cross-section shapes for pp values of 0.0 and 2.0 are depicted in
Referring now to
Initially, a preliminary mixer flowpath is defined based on desired engine operating conditions and with the cross-section shape of each mixer lobe 206 initialized using a pp value between 0.0 and 2.0. In a particular preferred implementation, the value of pp is initialized to 0.4. However, any one of numerous other values may be selected.
After the preliminary flowpath is defined, various mixer and mixer flowpath parameters are selectively perturbed to obtain the finalized design. In particular, the mixer flow area ratio (i.e., mixer inlet area/mixer outlet area) and the overall mixer length are selectively perturbed. The mixer lobe peak 404 and mixer lobe valley 406 profiles (see e.g.,
It was noted above that the mixer 138 described herein provides increased performance relative to presently known, standard mixers. For reference purposes, perspective, side, and end views, respectively, of an embodiment of an exemplary standard mixer 800 are depicted in
The performance improvements provided by the mixer 138 described herein may most clearly be seen by looking at
With reference first to
The aerodynamic mixer 138 described herein provides improved mixing efficiency and engine performance by exhibiting less pressure loss, a more uniform exit flow temperature profile, and more uniform mixing than is possible with a standard, parallel wall mixer. The mixer 138 described herein has been proven, via testing, to reduce engine thrust specific fuel consumption by more than 0.5% as compared to an engine equipped with a standard mixer design. The skilled artisan will readily appreciate that a reduction in specific fuel consumption of this magnitude (i.e., >0.5%) is not non-trivial, but is rather quite significant. Indeed, reductions in specific fuel consumption on the order of 0.25% are generally thought of as significant. As a result, the magnitude reduction in specific fuel consumption wrought by the mixer described herein was wholly unexpected.
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.
This invention was made with Government support under NAS3-97151 awarded by NASA. The Government has certain rights in this invention.