Patent Application
20230417256
The present application is directed generally to turbomachinery rotors and more particularly to shrouded impellers for centrifugal compressors and blowers.
Turbomachinery can be required to operate at wide operational ranges with respect to fluid flow rates. Flow rate has been controlled with a variable geometry diffuser, which can adjust a fluid flow rate by altering a diffuser width, or a fixed or variable area casing bypass (e.g., a bleed port), which removes a portion of the fluid flow. Flow rate can also be controlled by adjusting a machine rotational velocity (RPM) or a position of inlet guide vanes to throttle fluid flow to the rotor, however this also changes a pressure ratio or head. It is advantageous to be able to independently control the pressure ratio or head and flow rate of turbomachinery to meet changing operational demands while minimizing power consumption. A need exits for an impeller with a truly variable geometry that can efficiently adjust a flow rate of the turbomachinery independent of head.
In one aspect, a shrouded impeller includes an impeller having a plurality of blades and configured to rotate about an axis, and a shroud disposed adjacent to the impeller and configured to corotate about the axis with the impeller and translate axially relative to the impeller.
In another aspect, a method of varying a geometry of a flow area of a shrouded impeller includes rotating an impeller and a shroud disposed adjacent to the impeller about an axis and axially translating the shroud relative to the impeller to increase or decrease a rate of flow between the shroud and the impeller.
The present summary is provided only by way of example, and not limitation. Other aspects of the present disclosure will be appreciated in view of the entirety of the present disclosure, including the entire text, claims and accompanying figures.
While the above-identified figures set forth embodiments of the present invention, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention. The figures may not be drawn to scale, and applications and embodiments of the present invention may include features, steps and/or components not specifically shown in the drawings.
The present disclosure provides multiple embodiments of variable geometry shrouded impellers, which can be used to separately and independently control a flow rate and a pressure ratio or head of a centrifugal compressor or blower by varying a height at an impeller outlet. The disclosed variable geometry shrouded impellers can effectively reduce the size of a centrifugal compressor or blower having a radial flow by shrinking a flow capacity during operation, while maintaining the same head, which can be controlled by the rotational speed of the impeller and blade geometry or inlet angle. The fluid flow rate and developed head can be controlled by axially translating the shroud to reduce a height of the impeller blades and thereby a height at the impeller outlet. The disclosed variable geometry shrouded impellers can be used with variable or fixed speed machines and do not require bleed ports, variable geometry diffusers, changes in rotational speed, or throttling of flow with guide vanes to adjust the fluid flow rate. Although, discussion focuses on use of the disclosed variable geometry shrouded impeller in a centrifugal compressor or blower, it will be understood that embodiments disclosed herein can be adapted for a variety of rotor applications including radial turbines and pumps.
Impeller 10 is configured to rotate on axis A (e.g., via a rotor shaft as known in the art) with an axial inlet and radial outlet fluid flow. Impeller 10 includes two-dimensional (fully axially-extending) blades 18 that extend outward from hub 12. Bore 32 extends through a center of hub 12 including a center of shaft portion 14 and disk portion 16. Bore 32 is configured to receive, for example, a tie rod of a turbomachine. Disk portion 16 extends radially outward from shaft portion 14. Hub 12 has inlet side 42 and outlet side 44 opposite inlet side 42. Inlet side 42 is configured to be positioned at a fluid inlet location of a turbomachine. Outlet side 44 is defined by disk portion 16. Hub 12 has radially inner end 46 defined by bore 32 and radially outer end 48 defined by an outer diameter of disk portion 16. Blades 18 extend from leading edge 22 adjacent to inlet side 42 to trailing edge 23 adjacent to radially outer end 48. Blade tips 24 extend from leading edge 22 to trailing edge 23 and can generally follow a curvature of an outer surface (opposite radially inner end 46) of hub 12.
In some embodiments, blade leading edges 22 can be angled with respect to axis A to provide an optimal inlet angle to improve rotor efficiency as known in the art. For example, in some embodiments, leading edges 22 can be angled up to 40 degrees with respect to axis A such that portions of blades 18 along leading edges 22 are not fully axially extending. In some embodiments, variable geometry shrouded impeller 24 can be used in combination with a variable or fixed inlet guide vane (shown in
Shroud 26 is disposed adjacent to impeller 10 and is configured to corotate on axis A with impeller 10 and to translate axially relative to impeller 10 to increase or decrease height ho at outlet 30 to adjust a fluid flow capacity and fluid flow rate through variable geometry shrouded impeller 24. Inlet opening 38 is configured to be positioned at the fluid inlet location of a turbomachine adjacent to inlet side 42 of impeller 10. Outlet edge 40 is configured to be positioned at variable axial locations adjacent to hub 12 at outlet side 44 and outlet end 48. Shroud 26 includes wall portion 34, which extends from inlet opening 38 to oppositely positioned outlet edge 40. Wall portion 34 can have a curvature generally following a curvature of the outer surface of hub 12. Wall portion 34 can be designed to accommodate blades 18 that have leading edges 22 that are not fully axially extending but, instead, angled with respect to axis A such that shroud 26 can be axially translated without interference from portions of blades 18 that cannot be received in hollow elements 36 as described below. An inner surface of wall portion 34 and the outer surface of impeller hub 12 define a fluid flow path.
Hollow elements 36 can extend radially outward from wall portion 34 (opposite the inner surface) from a position adjacent to inlet opening 38 to outlet edge 40. Hollow elements 36 can have a shape generally matching a shape of portions of blades 18. Hollow elements 36 open to the inner surface of wall portion 34. Hollow elements 36 are closed at outlet edge 40. Internal surfaces of hollow elements 36 can define a shape generally matching the two-dimensional (fully axially-extending) shape of portions of blades 18 aft of leading edges 20, and are sized to accommodate portions of blades 18, including blade tips 24 and portions of trailing edges 23. The openings defined by the internal surfaces of hollow elements 36 can be sized to minimize a gap between an outer surface of blades 18 and shroud 26. It will be appreciated by one of ordinary skill in the art that blades 18 can be designed with varying configurations as known in the art to provide optimal performance and that the shape defined by the internal surfaces of hollow elements 36 can be designed to match a shape of portions of blades 18 that are received in shroud 26. The opening defined by the internal surfaces of hollow elements 36 can have a depth that increases from inlet opening 38 to outlet edge 40 to accommodate blades 18. In some embodiments, hollow elements 36 can extend fully to shroud inlet opening 38. In some embodiments, hollow elements 36 can be axially offset from shroud inlet opening 38 to accommodate portions of blades 18 that are not fully axially extending, e.g., due to curvature of leading edges 22.
Blades 18 can be slidably received in hollow elements 36 with actuation of shroud 26 (i.e., axial translation toward impeller 10). In some embodiments, some contact can occur between blades 18 and internal surfaces of hollow elements 36 with axial translation of shroud 26. Blades 18 can be sized to provide minimum leakage at blade tips 22. In some embodiments, hollow elements 36 can be sized to minimally contact or rub outer surfaces of blades 18 with axial translation of shroud 26. Hollow elements 36 can be sized such that the force of shroud 26 with actuation overcomes friction, allowing blades 18 to be received in hollow elements 36. Hollow elements 36 can be sized to limit wear on blades 18 and/or internal surfaces of hollow elements 36 over time.
Inlet opening 38 can circumscribe or extend around a radially outer limit of leading edges 20 of impeller blades 18, such that upon axial translation of shroud 26 there is no contact between shroud 26 and blade leading edges 20. Inlet opening 38 can be defined by a solid ring without hollow elements 36. As previously noted, in some embodiments, hollow elements 36 can extend fully to inlet opening 38. The inlet height hi is the distance between an inner surface of wall portion 34 and an outer surface of impeller shaft portion 14 at inlet 28.
Outlet edge 40 is configured to be positioned at variable axial locations adjacent to hub 12 at outlet side 44 and outlet end 48. As illustrated, height ho is the distance between axial-facing surfaces adjacent to outlet edge 40 and outlet end 48 at outlet 30. Hollow elements 36 can extend to outlet edge 40, forming a portion of outlet edge 40. Hollow elements 36 are closed at a radially outer extent to cover a portion of trailing edges 23 when received in hollow elements 36.
Shroud 26 corotates with impeller 10 such that blades 18 are aligned with hollow elements 36 and can be received in hollow elements 36. Shroud 26 can be translated axially toward impeller 10. Impeller 10 maintains a constant axial position. In a fully open position (maximum ho), shroud inlet opening 38 can be positioned axially forward of impeller inlet side 42. In a fully reduced position (minimum ho), shroud inlet opening 38 can be substantially axially aligned with impeller inlet side 42. As illustrated in
As illustrated, in a fully open position (maximum ho), an inner surface of shroud wall portion 34 can be spaced from blade tips 22 adjacent inlet 28 and axially aligned with or axially overlapping blade tips 22 adjacent outlet 30. In a fully open position (maximum ho), blade tips 22 adjacent to trailing edges 23 can be received in shroud hollow elements 36. In a fully reduced position (minimum ho), a majority of the extent of blade tips 22 (from leading edge 22 to trailing edge 23) can be received in shroud hollow elements 36. In some embodiments, the full extent of blade tips 20 can be received in shroud hollow elements 36 in the fully reduced position. The extent to which blades 18 are received in hollow elements 36 can vary depending on the design of blades 18 and hub 12. In all embodiments, shroud 26 is designed to be able to corotate with impeller 10 while translating axially to receive blades 18 in hollow elements 36 and effectively increase or decrease a flow capacity and outlet height ho.
Shroud 26 can be translated axially along axis A prior to or during operation (i.e., during rotation of impeller 10) to accommodate changes in operational needs (e.g., air supply demand). For example, cabin air compressors used to compress air for use in an environmental control system of an aircraft may have varying operational demands depending on the number of passengers in the aircraft. A flight having a small number of passengers may require a lower air exchange than a flight at full capacity. Variable geometry shrouded impeller 24 allows for the control of the fluid flow rate through axial translation of shroud 26 to increase or decrease height ho at outlet 30, as needed for optimal operation. Variable geometry shrouded impeller 24 can be used to effectively increase or decrease the size of a compressor independent of head or pressure ratio, which could be maintained at a constant value. Impeller 10 can be a single speed or variable speed impeller. Variable geometry shrouded impeller 24 can change the flow rate for a single speed impeller, while maintain a constant rotor speed and head and varying the power consumed. The power consumed is reduced by reducing the flow rate while maintaining a constant rotor speed.
Varying actuation and support mechanisms can be used to move shroud 26 and can be designed to accommodate particular turbomachine assemblies. Shroud 26 can be fixed to a turbomachine rotor shaft to provide for corotation with impeller 10. Shroud 26 can be configured to be translated axially through operation of an actuator (shown in
Blades 60 extend from a hub (not shown) as described with respect to
Shroud 58 is shown schematically. Shroud 58 can be substantially similar to shroud 26 of variable geometry shrouded impeller 56 with the exception that hollow elements of shroud 58 are angled with respect to axis A in a manner consistent with blades 60 such that blades 60 can be received in hollow elements of shroud 58 with axial translation and rotation independent of impeller 56. Hollow elements of shroud 58 can be designed to receive blades 60A and 60B. As such, hollow elements accommodating blades 60A can have a different geometry than hollow elements accommodating blades 60B and, furthermore, may extend different lengths between a shroud inlet opening and shroud outlet edge to accommodate long blades 60A and short, splitter, blades 60B.
Variable geometry shrouded impeller 54 can be adapted for use in any shrouded impeller application for which a variable geometry is advantageous, including radial compressors, blowers, turbines, and pumps.
Experimental Results
Numerical analysis of a 2.5 pressure ratio compressor with a mass flow rate of 0.6 kg/s and rotational speed of 40K rpm was conducted for variable geometry shrouded impellers embodiments having a) two-dimensional (fully axially-extending) blades and b) three-dimensional blades oriented at a constant 33 degree angle relative to an axis of rotation. Up to 90.7% rotor efficiency was achieved with two-dimensional blades. Up to 94.4% rotor efficiency was achieved with the three-dimensional blades. It is expected that with CFD screening and/or combined use with an inlet guide vane, a rotor efficiency of greater than 96% will be possible. Use of an inlet guide vane can improve rotor efficiency when blade inlet angle is not optimum (e.g., less than 60 degrees relative to the axis of rotation). Use of an inlet guide vane may provide particular benefit in improving rotor efficiency for variable geometry shrouded impellers having two-dimensional blades.
As illustrated in
As illustrated in
The disclosed variable geometry shrouded impellers can be used to effectively adjust the size of compressors and blowers by separately controlling a flow rate and pressure ratio or head and changing a flow capacity by varying a height at an impeller outlet. The disclosed variable geometry shrouded impellers can be used with variable or fixed speed machines and do not require bleed ports, variable geometry diffusers, changes in rotational speed, or throttling of flow with guide vanes to adjust the fluid flow rate. It will be appreciated by one of ordinary skill in the art that the disclosed variable shrouded impellers can be adapted for a wide variety of applications that use centrifugal or radial compressors, blowers, turbines, and pumps.
Any relative terms or terms of degree used herein, such as “substantially”, “essentially”, “generally”, “approximately” and the like, should be interpreted in accordance with and subject to any applicable definitions or limits expressly stated herein. In all instances, any relative terms or terms of degree used herein should be interpreted to broadly encompass any relevant disclosed embodiments as well as such ranges or variations as would be understood by a person of ordinary skill in the art in view of the entirety of the present disclosure, such as to encompass ordinary manufacturing tolerance variations, incidental alignment variations, transient alignment or shape variations induced by thermal, rotational or vibrational operational conditions, and the like. Moreover, any relative terms or terms of degree used herein should be interpreted to encompass a range that expressly includes the designated quality, characteristic, parameter or value, without variation, as if no qualifying relative term or term of degree were utilized in the given disclosure or recitation.
Discussion of Possible Embodiments
The following are non-exclusive descriptions of possible embodiments of the present invention.
A shrouded impeller includes an impeller having a plurality of blades and configured to rotate about an axis, and a shroud disposed adjacent to the impeller and configured to corotate about the axis with the impeller and translate axially relative to the impeller.
The shrouded impeller of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations and/or additional components:
The shrouded impeller of any of the preceding paragraphs, wherein the shroud includes s a plurality of hollow elements configured to receive portions of the plurality of blades of the impeller with axial translation of the shroud relative to the impeller.
The shrouded impeller of any of the preceding paragraphs, wherein tips of the plurality of blades are received in the hollow elements.
The shrouded impeller of any of the preceding paragraphs, wherein an internal geometrical shape of the hollow elements substantially matches a shape of the plurality of blades.
The shrouded impeller of any of the preceding paragraphs, wherein blades of the plurality of blades extend parallel to the axis.
The shrouded impeller of any of the preceding paragraphs, wherein leading edges of the plurality of blades are disposed at an angle relative to the axis.
The shrouded impeller of any of the preceding paragraphs, wherein the angle is less than or equal to 40 degrees.
The shrouded impeller of any of the preceding paragraphs, wherein an inlet of the shroud circumscribes the leading edges of the plurality of blades.
The shrouded impeller of any of the preceding paragraphs, wherein blades of the plurality of blades extend at an angle relative to the axis, wherein each location of each blade is displaced by a first angle from a position of a fully axially extending blade.
The shrouded impeller of any of the preceding paragraphs, wherein the shroud is configured to be actuated circumferentially relative to the impeller with axial translation.
A method of varying a geometry of a flow area of a shrouded impeller includes rotating an impeller and a shroud disposed adjacent to the impeller about an axis and axially translating the shroud relative to the impeller to increase or decrease a rate of flow between the shroud and the impeller.
The method of the preceding paragraph can optionally include, additionally and/or alternatively, any one or more of the following features, configurations, additional components, and/or steps:
The method of any of the preceding paragraphs and further including receiving tips of blades in hollow elements of the shroud with axial translation of the shroud toward a hub of the impeller.
The method of any of the preceding paragraphs, wherein blades of the impeller extend parallel to the axis.
The method of any of the preceding paragraphs, wherein at least portions of blades of the impeller extend at an angle relative to the axis.
The method of any of the preceding paragraphs and further including actuating the shroud circumferentially relative to the impeller with axial translation.
The method of any of the preceding paragraphs and further including varying a geometry of an inlet guide vane upstream of the shrouded impeller with axial translation of the shroud, wherein varying the geometry of the inlet guide vane changes an inlet flow angle of the shrouded impeller.
While the invention has been described with reference to an exemplary embodiment(s), 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 invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.
