1. Field of the Invention
The present disclosure relates to injectors, and more particularly to injection such as used in fuel injectors for gas turbine engines, exhaust gas after treatment, fuel cell reformers, and the like.
2. Description of Related Art
A variety of devices are known for injecting or spraying liquids, and for atomizing liquids into sprays of fine droplets, such as for gas turbine engines, fuel cell reformers, fire sprinkler systems, agricultural sprayers, chemical processing, paint sprayers, and other similar applications. It is desirable in many applications for the spray angle of a nozzle or injector to change during operation. For example, during start up of a gas turbine engine, it is desirable for fuel nozzles to have a wide spray angle in order to position fuel flow in proximity with igniters, which are typically on the periphery of the surrounding combustor. After combustion has been initiated, it may be desirable to have a narrower spray angle to achieve deeper spray penetration into the combustor. These two different spray angles can be accomplished using nozzles with two stages, each having a different spray angle. The extra components required to produce the two stages require envelope space and add to part count. It may also be possible to change the spray angle by physically changing the nozzle geometry. This approach has not become main stream, due to the complications of actuating components to change the nozzle geometry.
Such conventional methods and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for improved injection. The present disclosure provides a solution for these problems.
A method of issuing a spray cone from a nozzle includes modulating flow to two separate first and second fluid circuits, each connected to a common injection point orifice to vary spray angle on a substantially hollow spray cone over time to create a full spray cone. Modulating can include controlling first and second flow modulators, connected to the first and second fluid circuits, respectively, to coordinate oscillating flow rate modulation of both of the first and second fluid circuits. Controlling can include controlling the oscillating flow rate modulation for the first flow modulator to be out of phase with, to be in antiphase with, to be vertically shifted in magnitude relative to, and/or to have an amplitude that is equal to that of the second flow modulator.
A nozzle system for injecting liquid includes a nozzle body defining a first circuitous flow channel and a swirl ante-chamber in fluid communication with the first flow channel, with an injection point orifice defined in the swirl ante-chamber. The first flow channel feeds into the swirl ante-chamber to impart a tangential flow component on fluids entering the swirl ante-chamber to generate swirl on a spray issuing from the injection point orifice. A second circuitous flow channel is defined in fluid communication with the swirl ante-chamber. The second flow channel feeds into the swirl ante-chamber to impart a tangential flow component on fluids entering the swirl ante-chamber.
A backing member is in fluid communication with the nozzle body. The backing member includes a first fluid inlet chamber having one or more flow passages defined through the backing member for fluid communication from the first fluid inlet chamber of the backing member to the first flow channel of the nozzle body, and a second fluid inlet chamber having one or more flow passages defined through the backing member for fluid communication from the second fluid inlet chamber of the backing member to the second flow channel of the nozzle body to change spray angle of the injection point orifice by apportionment of flow between the first and second fluid inlet chambers of the backing member.
A first flow modulator is included in fluid communication with the first fluid inlet. A second flow modulator is included in fluid communication with the second fluid inlet. The first and second flow modulators are configured to issue an oscillating flow to the first and second fluid inlets, respectively, to issue a full active spray cone from the injection point orifice.
A controller can be operatively connected to the first and second flow modulators to coordinate oscillating flow rate modulation of both. The oscillating flow rate modulation for the first flow modulator can be out of phase, e.g., in antiphase, with the oscillating rate flow modulation for the second flow modulator. The oscillating flow rate modulation for the first flow modulator can be vertically shifted in magnitude relative to the oscillating flow rate modulation for the second flow modulator. The oscillating flow rate modulation for the first flow modulator can have an amplitude that is equal to that of the second flow modulator. It is contemplated that the oscillating flow rate modulation for the first flow modulator can be in antiphase with, can be vertically shifted in magnitude relative to, and can have an amplitude that is equal to that of the second flow modulator.
The flow passages of the first and second flow channels can feed into the swirl ante-chamber to impart a counter-swirling tangential flow component on fluids entering the swirl ante-chamber. It is also contemplated that the flow passages of the first and second flow channels can feed into the swirl ante-chamber to impart a co-swirling tangential flow component on fluids entering the swirl ante-chamber. The nozzle system can include additional swirl ante-chambers, each having a separate injection point orifice, each swirl ante-chamber being in fluid communication with the first and second flow channels.
These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.
So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:
Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of a nozzle system in accordance with the disclosure is shown in
Referring first to
This geometry is generalized by geometry in which the liquid is given a directional bias from features in the geometry, i.e., passages 114 which could be holes, slots, or the like, which enter into one or more separate passages, i.e., flow channel 104. The flow feeds from flow channel 104 into swirl ante-chamber 106 with a bias in direction, so as to impart swirl on fluids flowing into swirl ante-chamber 106. The flow continues to spin before finally exiting out of orifice 108. Multiple swirl ante-chambers and respective orifices may be used for multi-point injection. Note that for simplicity only one the fluid circuit is shown in
The configuration in
With reference now to
With reference now to
Nozzle system 200 provides the advantage of variable swirl angle ability. With two or more channels feeding into the swirl ante-chambers, if the directional geometry is set to counter-swirl into the swirl ante-chambers, for example, there is a large degree of controllability on the swirl angle. For example, fixing the total flow rate into the injector (say 100 lb/hr or 0.756 kg/s), if all of the flow goes through only 1 of the 2 channels, it will give a certain spray angle out of the exit orifice(s), for example 60°. If the flow is split evenly between both channels, e.g., 50 lb/hr (0.38 kg/s) in each channel for 100 lb/hr (0.756 kg/s) total injector flow, then the spray angles out of the exit orifice(s) will be reduced because of the opposite swirl directions feeding into the swirl ante-chambers. This swirl angle can be completely controlled by controlling the flow split between the channels.
Referring again to
Referring now to
In
The flow modulations described above can be modified so the spray can be profiled for specific applications. For example, if a uniform mass distribution is desired, the flow control of the modulation can be biased to spend more time at wider angles than narrow angles. The profile can also be tailored to reduce hot spots, e.g., in combustion applications, and give a better temperature profile at the exit of the combustor, leading to increased engine life. With active fluid control, e.g., from controller 222, the spray angle could be varied instead of the mass flow rate as in traditional active fluid control, to stabilize instabilities in a flame.
Referring now to
A method of issuing a spray cone from a nozzle includes modulating flow to two separate first and second fluid circuits, each connected to a common injection point orifice, e.g. injection point orifice 208, to vary spray angle on a substantially hollow spray cone over time to create a full spray cone. Modulating can include controlling first and second flow modulators, e.g., flow modulators 216 and 218, connected to the first and second fluid circuits, respectively, to coordinate oscillating flow rate modulation of both of the first and second fluid circuits. Controlling can include controlling the oscillating flow rate modulation for the first flow modulator to be out of phase with, to be in antiphase with, to be vertically shifted in magnitude relative to, and/or to have an amplitude that is equal to that of the second flow modulator as described above.
Traditional swirl type injectors produce a hollow cone. However, a solid cone of atomized liquid, as provided by the full active spray cone disclosed herein, is desirable in that it can distribute over a larger area, thus having quicker evaporation rates than traditional injectors and nozzles. In the exemplary context of fuel combustion, this can provide a more distributed flame than traditional injection techniques. This can result in substantially reduced emissions, increased operability, and more uniform temperature distributions which can improve engine life.
Spray angle control as described herein provides the potential for improved advanced active combustion control. Since the spray angle can be controlled fluidically instead of mechanically, a faster response time can be achieved than in other active combustion control devices. This can be realized by changing the spray angles in a controlled method to counteract unwanted thermal-acoustic instabilities, i.e. rumble, without the need to change the overall mass flow rate of the injector, but instead by simply adjusting the flow splits between flow channels. Additionally, due to the fluidic control of exemplary embodiments described herein, it may be possible to find a fluidically controllable instability, which could also be used to control the unwanted thermal-acoustic instabilities.
While described above in the exemplary context of fuel injection, those skilled in the art will readily appreciate that any suitable fluid can be swirled as described above. For example, the principles used to swirl fluids in nozzle system 200 can similarly be used for controlling air. In such applications, air is split into two separate inlet chambers, which respectively feed into similarly oriented directional passages. This allows for the air flow angle to be controlled fluidically, very similar to the way the liquid spray angle is controlled in nozzle system 200. Any other exemplary spray application can benefit from the systems and methods described herein without departing from the scope of this disclosure, including for example fuel cell reformers or exhaust gas after treatment, so the catalyst can receive a uniform distribution of fluid, fire sprinkler systems, agricultural sprayers, chemical processing, paint sprayers, and the like. Fluids such ad fuel, air, gas, oil, paint, water, or any other suitable fluid can be issued using the systems and methods described herein.
While shown and described above in the exemplary context of fuel injection for gas turbine engines, those skilled in the art will readily appreciate that any suitable fluids can be used and that any other suitable applications can make use of nozzles and injectors as described herein without departing from the spirit and scope of this disclosure. While described above in the exemplary context of multi-point injection, those skilled in the art will readily appreciate that any suitable number of injection points can be used, including single point injection, without departing from the spirit and scope of this disclosure.
The methods and systems of the present disclosure, as described above and shown in the drawings, provide for injection with superior properties including active full spray cones. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.