Air-oil separation system for an oil sump in a gas turbine engine

Abstract

An air-oil separation system for an oil sump of a gas turbine engine includes: (a) an air-oil separator for separating an air-oil mixture into an oil component and an air component; (b) at least one air-oil inlet section for inputting the air-oil mixture from the oil sump into a separation chamber of the air-oil separator, the air-oil inlet section including an inlet heat exchanger section having an inlet coolant flow passage for providing coolant to flow through the flow passage to cool the air-oil mixture inputting into the air-oil inlet section; (c) at least one oil outlet for flowing the oil component from the separation chamber of the air-oil separator back to the oil sump; and (d) an air outlet for flowing the air component out of the separation chamber of the air-oil separator.

Description

Technical Field

[0001] This disclosure relates to an air-oil separation system for an oil pan in a gas turbine engine. Background Technology

[0002] Gas turbine engines typically consist of a low-pressure compressor and a low-pressure turbine driven by a low-pressure shaft, and a high-pressure compressor and a high-pressure turbine driven by a high-pressure shaft. Both the low-pressure and high-pressure shafts are supported by bearings, which are lubricated by oil in the oil pan. Some gas turbine engines may be equipped with an air-oil separator to separate air and oil from the air-oil mixture in the oil pan, returning the separated oil to the oil pan while expelling the separated air from the oil pan. Attached Figure Description

[0003] The features and advantages of this disclosure will be apparent from the following description of various exemplary embodiments, as shown in the accompanying drawings, wherein the same reference numerals generally denote the same, functionally similar and / or structurally similar elements.

[0004] Figure 1 This is a schematic partial cross-sectional side view of an exemplary high-bypass turbofan jet engine, according to aspects of this disclosure.

[0005] Figure 2 Based on aspects of this disclosure, in Figure 1 74 details captured Figure 1 A magnified detail view of the engine section.

[0006] Figure 3 Based on this disclosure, Figure 2 Detailed view of the air-oil separation system.

[0007] Figure 4 Based on aspects of this disclosure, in Figure 3 A magnified cross-sectional detail view of the air-oil inlet section, taken at point 114.

[0008] Figure 5 Based on aspects of this disclosure, from Figure 3 The view Figure 5-5 Rear view of the air-oil separation system taken from the image.

[0009] Figure 6 Based on aspects of this disclosure, in Figure 4 A cross-sectional view of the air-oil inlet section taken at plane 6-6.

[0010] Figure 7 Based on aspects of this disclosure, from Figure 3 The view Figure 7-7 Cut off Figure 3Front view of the air-oil separation system.

[0011] Figure 8A Based on aspects of this disclosure, from Figure 3 The plane was cut off at point 8-8, passing through Figure 3 A partial rear cross-sectional view of a portion of the separator housing.

[0012] Figure 8B According to aspects of this disclosure, a portion of the separator housing is depicted with... Figure 8A The alternative arrangement shown.

[0013] Figure 8C According to aspects of this disclosure, a portion of the separator housing is depicted with... Figure 8B The alternative arrangement shown.

[0014] Figure 8D According to aspects of this disclosure, a portion of the separator housing is depicted with... Figure 8A The alternative arrangement shown.

[0015] Figure 9 Based on aspects of this disclosure, in Figure 8B The plane cut at point 9-9 Figure 8B A partial cross-sectional side view of the separator housing.

[0016] Figure 10 Based on aspects of this disclosure, in Figure 8C The plane is cut off at 10-10. Figure 8C A partial cross-sectional side view of the separator housing.

[0017] Figure 11 This is a public aspect. Figure 3 The side view of an optional air-oil separation system shown.

[0018] Figure 12 Based on aspects of this disclosure, in Figure 11 At point 12-12 on the plane, for Figure 11 A partial cross-sectional rear view of a portion of the optional separator housing.

[0019] Figure 13 Based on this disclosure, Figure 3 Side view of the optional air-oil separation system shown.

[0020] Figure 14 Based on aspects of this disclosure, in Figure 13 224 details Figure 13 A magnified partial cross-sectional detail view of the inner first wall portion.

[0021] Figure 15This is a schematic block diagram of the architecture of an air-oil separation system using air as a coolant, according to aspects of this disclosure.

[0022] Figure 16 This is a schematic block diagram of the architecture of an air-oil separation system that uses fuel as a coolant, according to aspects of this disclosure.

[0023] Figure 17 This is a schematic block diagram of an air-oil separation system architecture using oil as a coolant, according to aspects of this disclosure. Detailed Implementation

[0024] The features, advantages, and embodiments of this disclosure will be apparent or obvious upon consideration of the following detailed description, accompanying drawings, and claims. Furthermore, the following detailed description is exemplary and intended to provide further explanation, without limiting the scope of the claimed disclosure.

[0025] Various embodiments of this disclosure will be discussed in detail below. While specific embodiments are discussed, they are for illustrative purposes only. Those skilled in the art will recognize that other components and configurations can be used without departing from this disclosure.

[0026] As used herein, the terms “first” and “second” are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of the components.

[0027] The terms "upstream" and "downstream" refer to the relative directions of fluid flow within a fluid path. For example, "upstream" refers to the direction from which the fluid flows, and "downstream" refers to the direction from which the fluid flows.

[0028] Known gas turbine engines include a low-pressure compressor and a low-pressure turbine driven by a low-pressure shaft, and a high-pressure compressor and a high-pressure turbine driven by a high-pressure shaft. Both the low-pressure and high-pressure shafts are supported by bearings, which are lubricated by oil in an oil pan. In some gas turbine engines, an air-oil separator is installed to separate air and oil from the air-oil mixture in the oil pan, returning the separated oil to the oil pan while expelling the separated air. However, some conventional air-oil separators may not effectively separate oil from air, causing oil particles to be discharged from the separator along with the air. This leads to increased engine oil consumption, and the engine oil may not be adequately cooled in the oil pan, thus failing to effectively lubricate the bearings.

[0029] This invention aims to solve the aforementioned problems by incorporating a heat exchanger into the air-oil separator, thereby improving the cooling of the air-oil mixture within the separator. Cooling the air-oil mixture within the separator increases the density difference between oil and air molecules, causing oil molecules to coalesce into larger droplets, making separation easier.

[0030] Now refer to the attached diagram, Figure 1 This is a schematic cross-sectional side view of an exemplary high-bypass turbofan jet engine 10 (hereinafter referred to as "engine 10"), which may include various embodiments of the present disclosure. Although the present disclosure will be further described below with reference to a ducted turbofan engine, it is also applicable to general gas turbine engines or general turbomachinery, including turbojet engines, turboprop engines, and turboshaft gas turbine engines, including marine and industrial turbine engines (also referred to as aerospace-derived gas turbine engines) and auxiliary power units. Furthermore, the present disclosure is not limited to... Figure 1 The ducted fan turbine engine shown can also be applied to unlined fan (UDF) turbine engines. For example... Figure 1 As shown, the engine 10 has a longitudinal centerline axis 12 extending from the upstream end 70 of the engine 10 to the downstream end 72 of the engine 10, for reference only. The longitudinal centerline axis 12 may define the longitudinal direction (L) of the engine 10, the radial direction (R) extending outward from the longitudinal centerline axis 12, and the circumferential direction C extending around the longitudinal centerline axis 12.

[0031] Generally, engine 10 may include fan assembly 14 and turbocharged engine 16 disposed downstream of fan assembly 14. Turbocharged engine 16 typically includes a housing 18 defining an annular inlet 20. Housing 18 encloses or at least partially forms the following components in a series flow relationship: a compressor section including a low-pressure (LP) compressor 22, a high-pressure (HP) compressor 24, and a combustor 26; a turbine section including a high-pressure turbine 28 and a low-pressure turbine 30; and an exhaust nozzle section 32. High-pressure rotor shaft 34 drivesly connects HP turbine 28 to HP compressor 24, HP compressor 24, HP turbine 28, and HP rotor shaft 34 defining a high-pressure spool 29. Low-pressure (LP) rotor shaft 36 drivesly connects low-pressure turbine 30 to low-pressure compressor 22, LP compressor 22, LP turbine 30, and low-pressure rotor shaft 36 defining a low-pressure spool 31. The low-pressure rotor shaft 36 can also be connected to the fan shaft 38 of the fan assembly 14 via a reduction gearbox assembly 40 (only a portion is shown in the figure), such as in a gear-driven or indirect-drive configuration. The LP rotor shaft 36, and the resulting low-pressure shaft 31, are supported by the LP rear bearing 50 and the LP front bearing 52. Similarly, the HP rotor shaft 34 is supported by the high-pressure rear bearing 54 and the high-pressure front bearing 56. As will be described in detail below, the low-pressure rear bearing 50, the low-pressure front bearing 52, the high-pressure rear bearing 54, and the high-pressure front bearing 56 can all be arranged in the oil pan (…). Figure 1 Inside (not shown), the oil pan provides oil flow to lubricate the bearing.

[0032] Engine 10 may also include an accessory gearbox 47. Although Figure 1 Not shown, but the accessory gearbox 47 can be mechanically connected to an intermediate gearbox (not shown) driven by the high-voltage spool 29 via a drive shaft (not shown) extending through one of the struts 46. The high-voltage spool 29 drives the accessory gearbox 47, thereby driving various accessories (not shown) mounted on the accessory gearbox 47. For example, one or more hydraulic pumps and one or more oil pumps can be mounted on and driven by the accessory gearbox 47.

[0033] like Figure 1 As shown, the fan assembly 14 includes a plurality of fan blades 42 connected to a fan shaft 38 and extending radially outward. An annular fan housing or nacelle 44 circumferentially surrounds the fan assembly 14, or at least a portion of the turbocharged engine 16, or both. The nacelle 44 may be supported relative to the turbocharged engine 16 by a plurality of circumferentially spaced outlet guide vanes or struts 46. Furthermore, at least a portion of the nacelle 44 may extend to cover the outer portion of the turbocharged engine 16, thereby forming a bypass airflow passage 48 therebetween.

[0034] During operation, air 58 enters the nacelle 44 at the nacelle inlet 60. A portion of the air 58 enters the annular inlet 20 as compressor inlet airflow 64, which is compressed by the LP compressor 22 and HP compressor 24 to form compressed air 66. Another portion of the air 58 enters the fan assembly 14 and is propelled by the fan blades 42 into the bypass airflow passage 48, thus providing bypass airflow 62. The compressed air 66 from the high-pressure compressor 24 enters the combustor 26, where it mixes with fuel to form a fuel-air mixture. This mixture is ignited and burned within the combustor 26, producing combustion gases 68. The combustion gases 68 further flow downstream into the HP turbine 28 and LP turbine 30, thereby rotating the HP rotor shaft 34 and LP rotor shaft 36. The rotation of the LP rotor shaft 36 also drives the fan shaft 38 via the reduction gearbox assembly 40. Subsequently, the combustion gases 68 are discharged through the jet exhaust nozzle section 32.

[0035] Figure 2 Based on aspects of this disclosure, from Figure 1 74 details captured Figure 1 A magnified detailed view of the engine section. (Example) Figure 2 As shown, the bearing support structure 76 supports the front bearing 52 of the LP shaft, and the shaft support member 77 is connected to the bearing support structure 76 and supports the LP rotor shaft 36. Figure 2 Only one low-pressure front bearing 52 is shown, but multiple low-pressure front bearings 52 may be included. The bearing support structure 76 and the shaft support member 77 define an oil pan 78 for containing oil (not shown) to be supplied to the low-pressure front bearing 52 for lubrication. The oil pan 78 is disposed within the pressurized air chamber 23. Figure 2(Generally shown in the diagram) Inside, the pressurized air chamber 23 is pressurized by, for example, compressor bleed air 64a. The bearing support structure 76 may include a front oil pan seal portion 79, and the shaft support structure 77 may include a rear oil pan seal 83. For example, the front oil pan seal 79 engages with one or more shaft seals 85, which may be formed as part of the fan shaft 38. The shaft seal 85 may be a labyrinth seal, or any other type of carbon gas seal and oil seal. Similarly, the shaft support member 77 includes a rear oil pan seal portion 83 that engages with one or more shaft seals 87, which may, for example, be formed as part of the LP rotor shaft 36. The shaft seal 87 may also be a labyrinth seal, or any other type of carbon gas seal and oil seal. The shaft seals 85 and 87 seal the oil pan 78 to prevent oil leakage from the oil pan 78 due to the pressure in the compressed air chamber 23 being higher than the pressure in the oil pan 78. However, some leakage may occur in the shaft seals 85 and 87, causing some compressor bleed air 64a from the compressed air chamber 23 to leak into the oil pan 78, thus forming an air-oil mixture 90 (shown schematically only in the figure) in the oil pan 78. An air-oil separation system 80 is provided within the oil pan 78, as will be described in detail below. At least a portion of the air-oil separation system 80 is driven by the low-pressure rotor shaft 36, making the air-oil separation system 80 a centrifugal air-oil separator used to separate air from oil in the air-oil mixture 90. As will be described in detail below, the coolant supply source 184 supplies coolant to the air-oil separation system 80 via the coolant supply line 186 and receives coolant from the air-oil separation system 80 via the coolant return line 188. In certain situations (as described below), coolant can be supplied to other components of engine 10 instead of returning to coolant supply source 184 via coolant return line 188. Furthermore (as described below), air separated from air-oil mixture 90 can be discharged from engine 10 via exhaust port 189. Figure 1 ).

[0036] Figure 3 Based on this disclosure, Figure 2 Detailed view of the air-oil separation system 80. Figure 3 The bearing support structure 76 is omitted in the text. Figure 2The oil sump 78 surrounding the air-oil separation system 80 is generally indicated by reference numeral 78. The air-oil separation system 80 includes an air-oil separator 81 having a separator housing 82, a first end wall 100, a second end wall 104, and a separator shaft 144. The separator housing 82, the first end wall 100, and the second end wall 104 define a separation chamber 112. As will be described in more detail below, the air-oil separator 81 is used to separate an air-oil mixture 90 into an oil component 92 (e.g., de-air-oil molecules) and an air component 94 (e.g., de-oiled air molecules). The air-oil separation system 80 also includes at least one air-oil inlet portion 84 for feeding the air-oil mixture 90 from the oil sump 78 into the separation chamber 112. As will be described in detail below, the air-oil inlet section 84 includes a heat exchanger section (described below) for providing a coolant flow therethrough to cool the air-oil mixture 90 entering the air-oil inlet section 84. The air-oil separation system 80 further includes at least one oil outlet 86 for allowing oil component 92 to flow from the separation chamber 112 to the oil sump 78; and an air outlet 88 for allowing air component 94 to flow from the separation chamber 112 to the exhaust port 189. Figure 2 ).

[0037] exist Figure 3 In this separator housing 82, a truncated conical wall 98 is included, which contains at least one housing wall coolant flow passage 158. The housing wall coolant flow passage 158 will be described in more detail below. A first end wall 100 is disposed at a first end 102 of the truncated conical wall 98, and a second end wall 104 is disposed at a second end 106 of the truncated conical wall 98. The first end wall 100 extends circumferentially along a longitudinal centerline axis 12' and has a first diameter 108. At least one air-oil inlet 84 passes through the first end wall 100, allowing an air-oil mixture 90 to flow into a separation chamber 112. The second end wall 104 also extends circumferentially along a longitudinal centerline axis 12' and has a second diameter 110, wherein the second diameter 110 is smaller than the first diameter 108. As described below, the air-oil mixture 90 enters the separation chamber 112 via the air-oil inlet 84, and the air-oil mixture 90 is separated into an oil component 92 and an air component 94 within the separation chamber 112.

[0038] Figure 4 Based on aspects of this disclosure, in Figure 3 A magnified cross-sectional detail view of the air-oil inlet section 84, taken at detail 114. Figure 5 Based on aspects of this disclosure, in Figure 3 The view Figure 5-5 Rear view of the air-oil separation system 80, taken from the location. Figure 6 Based on aspects of this disclosure, in Figure 4 A cross-sectional view taken at plane 6-6 through the air-oil inlet section 84. (Common reference) Figure 4 , Figure 5 and Figure 6 The air-oil inlet section 84 can be cylindrical and has an inlet centerline axis 116. For example... Figure 4 As shown, the air-oil inlet portion 84 includes a cylindrical outer wall 118, a cylindrical inner wall 120, a cylindrical core 122, a first inlet end wall 124, and a second inlet end wall 126. An air-oil mixture inlet channel 128 is disposed between the cylindrical outer wall 118 and the cylindrical inner wall 120, through which the air-oil mixture 90 enters from the oil pan 78 (… Figure 3 ) flows into the separation chamber 112 through the air-oil mixture inlet channel 128. Figure 3 ).like Figure 4 and Figure 6 As shown, multiple air-oil passage supports 130 are arranged circumferentially around the inlet centerline axis 116 and are located between the outer cylindrical wall 118 and the inner cylindrical wall 120. Figure 4 and Figure 6 As shown, the inlet coolant flow passage 132 is defined between the cylindrical inner wall 120 and the cylindrical core 122. A plurality of coolant channel supports 134 are circumferentially spaced around the inlet centerline axis 116 and located between the cylindrical inner wall 120 and the cylindrical core 122. A coolant inlet 136 is disposed within the second inlet end wall 126 and is in fluid communication with the inlet coolant flow passage 132; a coolant outlet 138 passes through the second inlet end wall 126 and is in fluid communication with the inlet coolant flow passage 132. Coolant 140 (described below) flows through the coolant inlet 136, through the inlet coolant flow passage 132, and then through the coolant outlet 138. Therefore, the inlet coolant flow passage 132 functions as an inlet heat exchanger section 139, providing cooling for the air-oil mixture 90 flowing through the air-oil mixture inlet passage 128.

[0039] refer to Figure 5 and Figure 3 Multiple air-oil inlet portions 84 are disposed through the first end wall 100, and the multiple air-oil inlet portions 84 can be circumferentially spaced along the longitudinal centerline axis 12'. Figure 5 Eight air-oil inlet sections 84 are shown, but more or fewer than eight air-oil inlet sections 84 can also be provided. Furthermore, multiple oil outlets 86 are circumferentially spaced from each other around the longitudinal centerline axis 12'. Figure 3 As shown, each of the plurality of oil outlets 86 extends through the first end wall 100 and provides fluid communication between the separation chamber 112 and the oil pan 78, thereby allowing oil component 92 to flow from the separation chamber 112 to the oil pan 78.

[0040] like Figure 3 As shown, the separator shaft 144 is rotatably driven about the longitudinal centerline axis 12' of the air-oil separation system 80. The separator shaft 144 includes a shaft coolant inlet portion 146 and a shaft coolant outlet portion 148. The shaft coolant inlet portion 146 includes a shaft coolant inlet passage 150, and the shaft coolant outlet portion 148 includes a shaft coolant outlet passage 152. The shaft coolant inlet passage 150 receives coolant from the coolant supply line 186 (…). Figure 2 The coolant 140 is supplied by the shaft coolant outlet channel 152, which delivers the coolant 140 to the coolant return line 188. Figure 2 ).like Figure 3 As shown, and as Figure 5 As shown by the dashed lines, the first end wall 100 includes a plurality of first end wall coolant flow passages 142. Each of the plurality of first end wall coolant flow passages 142 is in fluid communication with a corresponding coolant inlet 136 of a shaft coolant inlet passage 150 and a respective air-oil inlet portion 84. Therefore, coolant 140 is supplied to the shaft coolant inlet passage 150, to the corresponding lines in the first end wall coolant flow passages 142, and to the corresponding portions in the air-oil inlet portions 84. Furthermore, each of the first end wall coolant flow passages 142 is in fluid communication with a housing wall inlet manifold 154. The housing wall inlet manifold 154 may be formed as part of the separator housing 82 and is used to receive coolant 140 from each of the first end wall coolant flow passages 142 and to distribute coolant 140 to at least one housing wall coolant flow passage 158.

[0041] Figure 7 Based on aspects of this disclosure, from Figure 3 The view Figure 7-7 Front view of the air-oil separation system 80, taken from the image. (Reference) Figure 7 and Figure 3 The second end wall includes multiple second end wall coolant flow passages 160 ( Figure 7(shown as dashed lines in the middle), these flow passages are circumferentially spaced around the longitudinal centerline axis 12. Each of the second endwall coolant flow passages 160 is in fluid communication with the housing wall outlet manifold 156 (which may be formed as part of the separator housing 82) and the shaft coolant outlet passage 152. The housing wall outlet manifold 156 is arranged to receive coolant 140 from each of at least one housing wall coolant flow passage 158 and to distribute coolant 140 to each of the second endwall coolant flow passages 160. Each of the second endwall coolant flow passages 160 is in fluid communication with the shaft coolant outlet passage 152 to provide coolant 140 to the shaft coolant outlet passage 152. The separator shaft 144 also includes a plurality of air outlet lines 162 arranged such that air component 94 can flow through these passages to exit from the separation chamber 112 to the exhaust port 189 ( Figure 2 ).

[0042] Figure 8A Based on aspects of this disclosure, in Figure 3 The section cut at point 8-8 in the mid-plane, passing through Figure 3 A partial rear cross-sectional view of a portion of the separator housing 82. Figure 8A In the diagram, the separator housing 82 is shown to include an outer wall 164 and an inner wall 166, with at least one coolant flow passage 158 disposed between the outer wall 164 and the inner wall 166. The coolant flow passage 158 serves as a heat exchanger 169 within the separator housing. Figure 8A In this aspect, at least one outer shell wall coolant flow passage 158 is a single outer shell wall coolant flow passage 168 extending in the circumferential direction C around the longitudinal centerline axis 12'. Figure 8A A portion of the separator housing 82 and a portion of a single housing wall coolant flow passage 168 are depicted, the single housing wall coolant flow passage 168 extending 360 degrees around the longitudinal centerline axis 12' and originating from the housing wall inlet manifold 154 ( Figure 3 ) Extends along the length direction to the outlet manifold 156 of the outer casing wall ( Figure 3 As described below, the coolant flow passage 158 in the outer casing wall also serves as a heat exchanger part of the air-oil separation system 80, providing cooling for the oil component 92 in the oil pan 78 and the oil component 92 in the separation chamber 112.

[0043] Figure 8B The diagram illustrates a portion of the separator housing 82 in accordance with an aspect of this disclosure. Figure 8A The alternative arrangement of the shown portion. Figure 8B In, with Figure 8A The same elements contain the same reference numerals, and the above description of these elements also applies. Figure 8B .exist Figure 8B In this configuration, multiple heat exchange elements 170 are included within a single housing wall coolant flow passage 168. Figure 8B The multiple heat exchange elements 170 in the separator housing may be, for example, heat exchange columns 172 connected to the outer wall 164 of the separator housing and connected to the inner wall 166 of the separator housing. The multiple heat exchange columns 172 may be spaced apart from each other in the circumferential direction C relative to the longitudinal centerline axis 12' within a single housing wall coolant flow passage 168.

[0044] Figure 9 Based on aspects of this disclosure, in Figure 8B A partial cross-sectional view of the separator housing 82 taken at plane 9-9. (See figure) Figure 9 As shown, multiple heat exchange columns 172 are spaced apart from each other along the length direction 174 within a single outer shell coolant flow passage 168 (see also...). Figure 3 Each of the heat exchange columns 172 increases the cooling efficiency of the individual shell wall coolant flow path 168 by increasing the surface area of ​​the separator shell heat exchanger 169.

[0045] Figure 8C The diagram illustrates a portion of the separator housing 82 in accordance with an aspect of this disclosure. Figure 8B A partial alternative arrangement. Figure 8C In, with Figure 8B The same elements in the drawings contain the same reference numerals, and the above description of these elements also applies. Figure 8C .exist Figure 8C In this process, multiple heat exchange elements 170 are also contained within a single housing wall coolant flow passage 168, but Figure 8C The plurality of heat exchange elements 170 may be, for example, heat exchange blocks (or units) 176 connected to the outer wall 164 and the inner wall 166 of the separator housing. The plurality of heat exchange blocks 176 include coolant flow passages 178 therethrough and may be spaced apart from each other in the circumferential direction C relative to the longitudinal centerline axis 12' within a single housing wall coolant flow passage 168.

[0046] Figure 10 Based on aspects of this disclosure, in Figure 8C A partial cross-sectional view of the separator housing 82 taken from plane 10-10. (See figure) Figure 10 As shown, multiple heat exchange blocks 176 are spaced apart from each other along the length direction 174 within a single outer shell coolant flow passage 168. Each of the heat exchange blocks 176 increases the cooling efficiency of the single outer shell coolant flow passage 168 by increasing the surface area of ​​the separator outer shell heat exchanger 169.

[0047] Figure 8D The diagram illustrates a portion of the separator housing 82 in accordance with an aspect of this disclosure. Figure 8A The alternative arrangement of the shown portion. Figure 8D In, with Figure 8A The same elements in the drawings contain the same reference numerals, and the above description of these elements also applies. Figure 8D .exist Figure 8D In this context, the outer casing coolant flow passage 158 is not a single outer casing coolant flow passage 168, but rather includes multiple outer casing coolant flow channels, including multiple inner casing coolant flow channels 180 and multiple outer casing coolant flow channels 182. The outer casing inlet manifold 154 ( Figure 3 It can be configured to supply coolant 140 to one or two of a plurality of inner housing coolant flow channels 180 or a plurality of outer housing coolant flow channels 182. Figure 8D In one aspect, a plurality of inner housing coolant flow channels 180 and a plurality of outer housing coolant flow channels 182 may be configured to be in the longitudinal direction 174 ( Figure 3 The manifold extends from the inlet manifold 154 of the outer casing wall to the outlet manifold 156 of the outer casing wall. Figure 3 ( ), extending generally along the longitudinal direction relative to the longitudinal centerline axis 12'. That is, the plurality of inner shell coolant flow channels 180 and the plurality of outer shell coolant flow channels 182 can be arranged as straight channels. In Figure 8D On another aspect, the multiple inner shell coolant flow channels 180 and the multiple outer shell coolant flow channels 182 can be arranged as spiral channels, which extend not only in the length direction 174 ( Figure 3 Furthermore, it extends in the circumferential direction C relative to the longitudinal centerline axis 12'.

[0048] Common Reference Figures 1 to 10 In the operation of the air-oil separation system 80, the air-oil separator 81 is driven by the separator shaft 144 and rotates within the oil pan 78. The air-oil mixture 90 retained in the oil pan 78 flows from the oil pan 78 into the separation chamber 112 through the air-oil inlet portion 84. Figure 3 In the process, the air-oil mixture 90 is cooled by the coolant 140 flowing through the inlet heat exchanger 139 of the air-oil inlet section 84, thereby forming a cooled air-oil mixture 90a. Figure 3 The air-oil mixture 90 flows into the separation chamber 112. The rotation of the air-oil separation system 80 creates a vortex 190 in the separation chamber 112 on the cooled air-oil mixture 90a. Figure 3Because the oil molecules in the cooled air-oil mixture 90a have a higher density, the centrifugal force of the cyclone 190 causes the cooled air-oil mixture 90a to separate into oil component 92 and air component 94. Therefore, the cyclone 190 separates the cooled air-oil mixture 90a, thereby obtaining oil component 92 and air component 94. The centrifugal force of the cyclone 190 also causes oil component 92 to flow towards the inner surface 192 of the inner wall 166 of the separator housing. Figure 3 ; Figure 8A ).like Figure 3 As shown, the rotation of the separator housing 82 causes oil component 92 to flow along the inner surface 192 of the separator housing inner wall 166 to at least one oil outlet 86. While flowing along the inner surface 192 of the separator housing inner wall 166, the oil component 92 is further cooled by coolant 140 flowing through at least one housing wall coolant passage 158. Then, the oil component 92 flows through at least one oil outlet 86 to exit the separation chamber 112 and enter the oil sump 78. Air component 94 flows out of the separation chamber 112 through at least one air outlet 88 and flows to the exhaust port 189. Figure 2 ).

[0049] Figure 11 Aspects according to this disclosure are shown. Figure 3 A side view of an alternative air-oil separation system 80a to the air-oil separation system 80 shown. Figure 11 In, with Figure 3 The same elements in the drawings contain the same reference numerals, and the above refers to... Figure 3 The provided component descriptions also apply to Figure 11 .exist Figure 11 In this alternative air-oil separation system 80a, there is an alternative air-oil separator 81a having an alternative separator housing 82a. Figure 3 The separator housing 82 shown is Figure 11 One difference in the alternative separator housing 82a shown is that the alternative separator housing 82a includes a blade structure 194, which may include one or more blades 200 extending inward from the inner surface 192 of the inner wall 166 of the separator housing into the separation chamber 112. Furthermore, wire mesh elements 196 are provided between the individual blades 200. Figure 11As shown, the wire mesh element 196 may consist of multiple wire mesh elements 196 arranged longitudinally between the individual blades 200 along the longitudinal direction 174. Each blade 200 may be a single blade extending along the inner surface 192 of the separator housing inner wall 166 and circumferentially around the longitudinal centerline axis 12. Alternatively, the blades 200 may consist of one or more helical blades extending circumferentially around the longitudinal centerline axis 12 and also extending helically along the longitudinal direction 174. The wire mesh element 196 atomizes the cooled air-oil mixture 90a, which rotates within the separation chamber 112 to further promote the separation of air component 94 and oil component 92. The blades 200 guide the cooled air-oil mixture 90a to vortex along a predetermined flow path (e.g., a helical flow path), thereby increasing the residence time of the cooled air-oil mixture 90a in the separation chamber 112 to further improve separation efficiency.

[0050] Figure 12 Based on aspects of this disclosure, in Figure 11 The plane cut at 12-12 Figure 11 A partial cross-sectional rear view of a portion of the alternative separator housing 82a. (See image) Figure 12 As shown, multiple wire mesh elements 196 are circumferentially spaced from each other along the longitudinal centerline axis 12. Furthermore, each impeller 200 may have multiple oil component flow openings 198, which are arranged along the inner surface 192 of the separator housing inner wall 166. The multiple oil component flow openings 198 are circumferentially spaced from each other and located between the individual wire mesh elements 196. The multiple oil component flow openings 198 allow oil component 92 ( Figure 11 The oil flows along the inner surface 192 of the inner wall 166 of the separator housing to the oil outlet 86, so that the oil component 92 can flow into the oil pan 78 through the oil outlet 86.

[0051] Figure 13 Based on this disclosure, Figure 3 Side view of an alternative air-oil separator 80b to the air-oil separator 80. Figure 13 In this alternative air-oil separation system 80b, an alternative air-oil separator 81b is included, which includes an alternative separator housing 82b, a first end wall 202, a second end wall 204, and a separator shaft 206. The alternative separator housing 82b includes a truncated conical wall 201 extending about a longitudinal centerline axis 12', which, together with the first end wall 202 and the second end wall 204, defines a separation chamber 222. However, compared to... Figure 3Unlike the truncated conical wall 98 shown, the truncated conical wall 201 does not include the outer shell coolant flow passage 158. A first end wall 202 is disposed at the first end 208 of the truncated conical wall 201, and a second end wall 204 is disposed at the second end 210 of the truncated conical wall 201. The second end wall 204 is fixedly connected to the separation shaft 206, such that rotation of the separation shaft 206 causes the second end wall 204 and the truncated conical wall 201 to rotate about the longitudinal centerline axis 12'.

[0052] The first end wall 202 includes an outer first end wall portion 212 and an inner first end wall portion 214. At least one air-oil inlet portion 213 (described in detail below) extends through the inner first end wall portion 214. Figure 3 Similar to the air-oil inlet section 84 shown, it may include multiple air-oil inlet sections 213, and the multiple air-oil inlet sections 213 may be arranged around the longitudinal centerline axis 12' in a manner similar to Figure 5 The air-oil inlet portions 84 shown are circumferentially spaced from each other. The inner first end wall portion 214 is fixedly mounted relative to the separation shaft 206 and connected to the bearing support structure 76 via, for example, one or more bolt connections 215. Figure 2 This ensures that when the separating shaft 206 rotates, the inner first end wall portion 214 does not rotate. The separating shaft 206 is connected to the inner first end wall portion 214 via a bearing member 218, such that the bearing member 218 provides support for the rotation of the separating shaft 206 about the longitudinal centerline axis 12'. The outer first end wall portion 212 is rotatably connected to the inner first end wall portion 214 via, for example, a bearing member 216. Therefore, when the separating shaft 206 rotates, the outer first end wall portion 212, which is connected to the first end 208 of the truncated cone wall 201, also rotates about the longitudinal centerline axis 12'.

[0053] The alternative air-oil separation system 80b further includes a plurality of oil outlets 220, which are arranged through an outer first end wall portion 212. The plurality of oil outlets 220 can be connected to... Figure 3 The multiple oil outlets shown are identical to 86, and are in line with... Figure 5 The oil outlets 86 shown are spaced apart from each other circumferentially in the same manner.

[0054] and Figure 3 Unlike the shown split shaft 144, split shaft 206 omits the shaft coolant inlet portion 146 and shaft coolant inlet channel 150, as well as the shaft coolant outlet portion 148 and shaft coolant outlet channel 152. However, split shaft 206 includes an air outlet 88 and an air outlet line 162. (This is in contrast to the aforementioned...) Figure 3 The situation is the same as shown, air component 94 flows through the separation chamber 222 to the exhaust port 189. Figure 2 Air outlet line 162 and air outlet 88.

[0055] Figure 14 Based on aspects of this disclosure, in Figure 13 Details captured at point 224 Figure 13 Enlarged, partial, cross-sectional, and detailed views of the air-oil inlet portion 213. The air-oil inlet portion 213 is fixedly connected to and extends through the inner first end wall portion 214. The air-oil inlet portion 213 includes an inlet heat exchanger portion 226. Figure 14 In one embodiment, the heat exchanger section 226 is arranged as a counter-flow heat exchanger 228. The counter-flow heat exchanger 228 includes a serpentine oil flow passage 230 and a serpentine coolant flow passage 232 located within the serpentine oil flow passage 230. The serpentine oil flow passage 230 includes an oil inlet 234 and at least one oil outlet 236. The serpentine coolant flow passage 232 includes a connection to a coolant supply line 186 (… Figure 2 The coolant inlet 238 is in fluid communication with the coolant return line 188. Figure 2 A coolant outlet 240 is fluidly connected to the air-oil mixture 90. An oil inlet 234 is arranged to introduce the air-oil mixture 90 from the oil sump 78, and at least one oil outlet 236 is configured to output the cooled air-oil mixture 90a to the separation chamber 222. The air-oil mixture 90 flows through a serpentine oil flow passage 230 in a first direction, while the coolant 140 flows through a serpentine coolant flow passage 232 in a second direction opposite to the first direction, thereby creating a countercurrent flow of the air-oil mixture 90 relative to the coolant 140. However, this disclosure is not limited to the countercurrent arrangement; in other embodiments (not shown), the air-oil mixture 90 and the coolant 140 flow in the same direction (i.e., a co-current flow arrangement). Therefore, the coolant 140 flowing through the serpentine coolant flow passage 232 provides cooling to the air-oil mixture 90 flowing through the serpentine oil flow passage 230, thereby obtaining the cooled air-oil mixture 90a delivered from the oil outlet 236 to the separation chamber 222. The counter-flow heat exchanger 228 can be configured as a tubular heat exchanger, a plate heat exchanger, a finned heat exchanger, an integral unit heat exchanger, or any other suitable heat exchanger type.

[0056] Back Figure 13The alternative air-oil separator 81b further includes a stationary cyclone separator 242 extending from the air-oil inlet portion 213 to the separation chamber 222. The stationary cyclone separator 242 may extend circumferentially about a longitudinal centerline axis 12', or may include multiple stationary cyclone separator portions circumferentially spaced about the longitudinal centerline axis 12'. The stationary cyclone separator 242 extends longitudinally 250 into the separation chamber 222 at a distance 252 from the first inner end wall 214, such that a gap 248 exists between the stationary cyclone separator 242 and the second end wall 204. The stationary cyclone separator 242 also includes multiple blades 244 for inducing swirl 246 in the cooled air-oil mixture 90a within the separation chamber 222. The multiple blades 244 may extend circumferentially about the longitudinal centerline axis 12', or may be helical blades extending longitudinally 250. Therefore, when the separator shaft 206 is driven to rotate by the low-pressure rotor shaft 36, the alternative separator housing 82b also rotates, and the cooled air-oil mixture 90a flows in the longitudinal direction 250, thereby causing the multiple impeller blades 244 to generate swirls 246, which in turn cause the cooled air-oil mixture 90a within the separator chamber 222 to generate swirls 246. (As described above) Figure 3 Similar to the description above, the cooled air-oil mixture 90a is separated into oil component 92 and air component 94 within the separation chamber 222. Air component 94 flows out of the separation chamber 222 to the exhaust port 189 via air outlet 88. Figure 2 Oil component 92 flows along the inner surface 254 of the truncated cone wall 201 to multiple oil outlets 220, and flows into the oil pan 78 through the multiple oil outlets 220.

[0057] This disclosure is not limited to the embodiments described above. In conjunction with... Figure 13 In another similar embodiment (not shown), a wire mesh element (similar to...) can be used. Figure 11 and Figure 12 The wire mesh element 196 is disposed along the fixed hydrocyclone 242 or along the truncated cone wall 201 to further guide the separation of the cooled air-oil mixture 90a. Furthermore, the shape of the air-oil separator 80 is not limited to... Figures 2 to 13 The truncated cone shape shown can also be replaced with other suitable shapes, such as a column.

[0058] like Figures 1 to 14 As shown, the coolant 140 can be composed of any one of air, fuel, or oil. For example, in Figure 2In this configuration, the coolant supply source 184 can be a bleed air source within the engine 10. Alternatively, the coolant supply source 184 can be a fuel source (not shown) that supplies fuel to the combustor 26. Yet another example is that the coolant supply source 184 can be cooling oil cooled by a heat exchanger (not shown) in another part of the engine 10. However, other suitable types of coolant, such as supercritical carbon dioxide or liquid hydrogen fuel, can also be used. Figures 15 to 17 This is a block diagram depicting the different flow structures of coolant 140 for each of the aforementioned coolant sources.

[0059] Figure 15 This is a schematic diagram of the architecture of an air-oil separation system 80 using air as a coolant 140, according to aspects of this disclosure. Figure 15 In the middle, and above Figures 1 to 14 Elements marked with the same reference numerals in the accompanying drawings are shown only in outline boxes for reference only. Figure 15 In the structure shown, compressor bleed air 64a is supplied to the pressurized air chamber 23 by the low-pressure compressor 22. (As described above...) Figure 2 Shaft seals 85 and 87 seal the oil pan 78, but leakage may occur in shaft seals 85 and 87, causing some compressor bleed air 64a to flow into the oil pan 78. Oil component 92 (e.g., degassed oil molecules) is delivered to the low-pressure front bearing 52 to lubricate it. The oil component 92 mixes with the compressor bleed air 64a (from the pressurized air chamber 23) within the oil pan 78 near shaft seals 85 and 87 to form an air-oil mixture 90. The air-oil mixture 90 is delivered to an air-oil separation system 80 (or, depending on the system employed, to an alternative air-oil separation system 80a or 80b), and, depending on the implementation of the system as described above, the air-oil mixture 90 is processed by the air-oil separation system 80 to obtain oil component 92 and air component 94. Figure 15 In the process, compressor bleed air 64b is used as coolant 140, and compressor bleed air 64b is sent to the air-oil inlet section 84. Figure 3 ) or air-oil inlet section 213 ( Figure 14The compressor bleed air 64b can be, for example, part of the compressor bleed air 64a supplied to the pressurized air chamber, or it can come from a bleed air line on the low-pressure compressor 22 that is different from the compressor bleed air line (not shown) used for the compressor bleed air 64a. In operation, the compressor bleed air 64b supplied to the air-oil inlet section 84 or the air-oil inlet section 213 flows out from the air-oil inlet section 84 or the air-oil inlet section 213 and can be supplied to the burner 26. As described above, in the air-oil separation system 80 (or air-oil separation system 80a or air-oil separation system 80b), the oil component 92 (e.g., degassed oil) is returned to the oil pan 78, while the air component 94 (e.g., de-oiled air) is sent to the exhaust port 189.

[0060] Figure 16 This is a schematic diagram and block diagram of the architecture of an air-oil separation system 80 using fuel as a coolant 140, according to aspects of this disclosure. Figure 16 In the middle, and above Figures 1 to 14 The same elements are shown using the same reference numerals and in boxes for reference purposes. Figure 16 In the architecture, with Figure 15 The same elements in the figures contain the same reference numerals, and the above refers to... Figure 15 The descriptions of these components also apply to Figure 16 The same components in. However, in Figure 16 In the structure shown, fuel 256 (engine 10) is mounted on the aircraft (not shown). Figure 1 (The fuel 258, which is stored on the aircraft, is supplied to engine 10. Fuel 258 is typically supplied to combustor 26.) Figure 1 It produces combustion gases 68, but can also be used for other purposes within the engine 10. For Figure 16 The air-oil separation system 80 shown has the following structure: a portion of fuel 258 can be delivered from the fuel tank 256 to the air-oil separation system 80 (or air-oil separation system 80a, or air-oil separation system 80b) via the fuel pump 260. Fuel 258 is supplied to the air-oil inlet section 84. Figure 3 )or Figure 13The air-oil inlet section 213 shown serves as coolant 140. In the air-oil separation system 80 (or air-oil separation system 80a, or air-oil separation system 80b), fuel 258 flows through the air-oil inlet section 84, providing cooling for the air-oil mixture 90 flowing through the air-oil inlet section 84. The air-oil separation system 80 (or air-oil separation system 80a, or air-oil separation system 80b) outputs oil component 92 (e.g., degassed oil) to the oil sump 78 and delivers air component 94 (e.g., de-oiled air) to the exhaust port 189. Fuel 258 is heated in the air-oil separation system 80 to obtain heated fuel 258a, which can then be supplied to the burner 26 for combustion to produce combustion gases 68.

[0061] Figure 17 This is a schematic block diagram of the architecture of an air-oil separation system 80 using oil as a coolant 140, according to aspects of this disclosure. Figure 17 In the middle, and above Figures 1 to 14 The same elements are shown using the same reference numerals and in boxes for reference purposes. Figure 17 In the architecture, with Figure 15 Elements that are identical in aspect contain the same reference numerals, and the above refers to... Figure 15 The descriptions of these components also apply to Figure 17 The same components in. However, in Figure 17 In the illustrated architecture, oil component 92 (e.g., degassed oil) from oil pan 78 can be recycled through air-oil separation system 80 (or air-oil separation system 80a, or air-oil separation system 80b) as coolant 140. Figure 17In the illustrated architecture, oil pump 262 is connected to oil pan 78 to obtain oil component 92 from oil pan 78. Oil component 92 may be supplied in part as oil component 92a to lubrication system 264 of engine 10. Oil component 92 is also supplied via oil supply line 266 to air-oil separator system 80 (or air-oil separator system 80a, or air-oil separator system 80b) as coolant 140. In air-oil separator system 80 (or air-oil separator system 80a or air-oil separator system 80b), cooling oil component 92b flows through air-oil inlet portion 84 to cool the air-oil mixture 90 flowing through air-oil inlet portion 84. Air-oil separator system 80 (or air-oil separator system 80a or air-oil separator system 80b) outputs oil component 92 (e.g., degassed oil) to oil pan 78 and delivers air component 94 (e.g., de-oiled air) to exhaust port 189. The cooled oil component 92b, heated in the air-oil separation system 80, can then be sent to the heat exchanger 268. The heat exchanger 268 uses the coolant source 270 to cool the coolant oil component 92b and outputs the cooled oil component 92c back to the oil pan 78.

[0062] As mentioned above Figure 1 The engine 10 may include an accessory gearbox 47, which may include one or more oil pumps. For example, at least one of the one or more oil pumps may be fluidly connected to an oil pan 78 to receive oil flow from and return oil flow to the oil pan 78, thereby providing lubrication for the low-pressure front bearing 52. One or more oil pumps may also be similarly arranged to provide oil flow to lubricate the low-pressure rear bearing 50, the high-pressure rear bearing 54, and the high-pressure front bearing 56. While the above... Figure 2 The description relates to an oil pan 78 disposed within a pressurized air chamber 23 for providing lubrication to a low-pressure front bearing 52, but as Figure 2 As shown, similar pressurized air chambers, oil pans, and air-oil separation systems can also be separately provided to lubricate the low-pressure rear bearing 50, the high-pressure front bearing 56, and the high-pressure rear bearing 54. That is, the low-pressure rear bearing 50, the high-pressure front bearing 56, and the high-pressure rear bearing 54 can all include similar arrangements as the pressurized air chamber 23, the oil pan 78, and the air-oil separation system 80. Alternatively, a single air-oil separation system 80 can be provided for a shared oil pan. For example, in such an arrangement, a system similar to... Figure 2 The oil pan and air-oil separator system are shown and driven by the accessory gearbox 47. For the low-pressure front bearing 52, low-pressure rear bearing 50, high-pressure front bearing 56, and high-pressure rear bearing 54, a separate unit without an air-oil separator can be provided. Figure 2The oil sump 78 of the air-oil separation system 80 shown collects oil pumped to each individual oil sump to lubricate each bearing. Each oil sump can be fluidly connected to a common oil sump, allowing oil from each oil sump at each bearing to flow to the common oil sump. The common oil sump may contain the air-oil separation system 80, which functions identically to the air-oil separation system 80 described above (or a standby air-oil separation system 80a or standby air-oil separation system 80b). The oil component 92 in the common oil sump can then be pumped back to the corresponding oil sump of the respective bearing, while the air component 94 is discharged from the common oil sump.

[0063] The above-mentioned aspects all provide an air-oil separation system that integrates a heat exchanger for cooling the air-oil mixture entering the system. This air-oil separation system is also installed within the oil pan and is driven to rotate by a rotary spool. By integrating the heat exchanger into the air-oil separation system, a better air-oil mixture separation process can be achieved, resulting in less oil in the air leaving the system. Therefore, oil consumption can be reduced. Furthermore, the degassing effect of the air-oil separation system also provides better lubrication and cooling efficiency for the oil within the oil pan.

[0064] While the foregoing description generally pertains to gas turbine engines, these engines can be applied in a wide variety of environments. For example, they can be used in aircraft as well as in non-aircraft applications such as power plants, ships, or oil and gas production. Therefore, this disclosure is not limited to aircraft applications.

[0065] Further aspects of this disclosure are provided in the following provisions.

[0066] An air-oil separation system for an oil sump in a gas turbine engine, the air-oil separation system comprising: an air-oil separator arranged to separate an air-oil mixture into an oil component and an air component; at least one air-oil inlet portion arranged to input the air-oil mixture from the oil sump into a separation chamber of the air-oil separator, the air-oil inlet portion including an inlet heat exchanger portion having an inlet coolant flow passage arranged to provide a coolant flow therethrough to cool the air-oil mixture input into the air-oil inlet portion; at least one oil outlet arranged to provide the oil component flowing from the separation chamber of the air-oil separator to the oil sump; and an air outlet arranged to provide the air component flowing out of the separation chamber of the air-oil separator.

[0067] According to the air-oil separation system described in the foregoing clause, the coolant is at least one of air, fuel, or oil.

[0068] According to any of the preceding clauses, the air-oil separation system wherein the inlet heat exchanger is arranged as a counter-flow heat exchanger, wherein the air-oil mixture flows in a first direction and the coolant flows in a second direction.

[0069] According to any of the preceding clauses, the air-oil separation system includes a counter-current heat exchanger comprising a serpentine coolant flow path and a serpentine oil flow path.

[0070] According to any of the preceding clauses, the air-oil separation system wherein the counter-current heat exchanger is configured as any one of a tubular heat exchanger, a plate heat exchanger, a finned heat exchanger, or an integral unit heat exchanger.

[0071] According to any of the preceding clauses, the air-oil separation system includes (a) a separator housing, (b) a first end wall, (c) a second end wall, and (d) a separator shaft, wherein the separation chamber is defined between the separator housing, the first end wall, and the second end wall.

[0072] According to any of the preceding clauses, the air-oil separation system wherein the air-oil separator is arranged to be rotatably driven by the separator shaft, and the rotational drive of the air-oil separator causes the oil component to flow along the inner surface of the separator housing and out from the at least one oil outlet into the oil pan.

[0073] According to any of the preceding clauses, the air-oil separation system further includes at least one wire mesh element extending from the air-oil inlet portion to the separation chamber, the at least one wire mesh element being arranged to atomize the air-oil mixture in the separation chamber.

[0074] According to any of the preceding clauses, the air-oil separation system comprises: (i) an outer first end wall portion fixedly connected to the separator housing and an inner first end wall portion fixedly connected to a support structure for mounting the air-oil separation system; (ii) a second end wall fixedly connected to the separator housing and the separator shaft, the separator shaft being arranged to rotatably drive the second end wall, the separator housing, and the outer first end wall portion about a longitudinal centerline axis of the air-oil separation system, and the inner first end wall portion being fixedly mounted relative to the separator shaft, the at least one air-oil inlet portion being arranged to extend through the inner first end wall portion, and the at least one oil outlet portion being arranged to extend through the outer first end wall portion.

[0075] According to any of the preceding claims, the air-oil separation system includes a truncated cone wall extending about a longitudinal centerline axis of the separator housing, a first end wall disposed at a first end of the truncated cone wall and including an outer first end wall portion and an inner first end wall portion, and a second end wall disposed at a second end of the truncated cone wall, the inner first end wall portion being fixedly mounted relative to the separator shaft, and the outer first end wall portion being rotatably connected to the inner first end wall portion, and the at least one air-oil inlet portion being connected to the inner first end wall portion.

[0076] The air-oil separation system according to any of the preceding clauses, wherein the air-oil separation system further includes a fixed cyclone separator extending from the air-oil inlet portion into the separation chamber.

[0077] According to any of the preceding clauses, the air-oil separation system wherein the stationary cyclone includes a plurality of blades arranged to induce the air-oil mixture in the separation chamber to generate a cyclone.

[0078] According to any of the preceding clauses, the air-oil separation system wherein the separator housing includes a truncated cone wall, the truncated cone wall including at least one housing wall coolant flow passage within the truncated cone wall and arranged to provide a coolant flow through it, thereby providing cooling to the air-oil mixture in the separation chamber.

[0079] According to any of the preceding clauses, the air-oil separation system wherein the at least one outer casing coolant flow passage includes a plurality of outer casing coolant flow channels.

[0080] According to any of the preceding clauses, the air-oil separation system wherein the truncated cone wall includes an outer wall of the separator housing and an inner wall of the separator housing, the at least one housing wall coolant flow passage is defined between the outer wall of the separator housing and the inner wall of the separator housing, and a plurality of heat exchange components are arranged within the at least one housing wall coolant flow passage.

[0081] According to any of the preceding clauses, the air-oil separation system wherein the plurality of heat exchanger components are heat exchange columns connected to the outer wall of the separator housing and to the inner wall of the separator housing.

[0082] According to any of the preceding clauses, in the air-oil separation system, the plurality of heat exchange columns are spaced apart from each other in the circumferential direction relative to the longitudinal centerline axis within the coolant flow passage of the single outer casing wall.

[0083] According to any of the preceding clauses, in the air-oil separation system, the plurality of heat exchanger components are heat exchange blocks (or units) connected to the outer wall of the separator housing and to the inner wall of the separator housing.

[0084] According to any of the preceding clauses, in the air-oil separation system, each of the plurality of heat exchange blocks includes a coolant flow path therethrough.

[0085] According to any of the preceding clauses, in the air-oil separation system, the plurality of heat exchange blocks are spaced apart from each other in the circumferential direction relative to the longitudinal centerline axis within the coolant flow passage of the single outer casing wall.

[0086] According to any of the preceding clauses, the air-oil separation system wherein the outer casing coolant flow path includes a plurality of outer casing coolant flow channels.

[0087] According to any of the preceding clauses, the multiple outer casing coolant flow channels include multiple inner casing coolant flow channels and multiple outer casing coolant flow channels.

[0088] According to any of the preceding clauses, the air-oil separation system includes a truncated cone wall with a blade structure on the inner surface of the truncated cone wall, the blade structure being arranged to generate swirl in the air-oil mixture within the separation chamber.

[0089] According to any of the preceding clauses, in the air-oil separation system, the first end wall is disposed at a first end of the truncated cone wall, the second end wall is disposed at a second end of the truncated cone wall, and the at least one air-oil inlet portion and the at least one oil outlet are disposed through the first end wall.

[0090] According to any of the preceding clauses, the air-oil separation system wherein the first end wall has a first diameter and the second end wall has a second diameter smaller than the first diameter, and the at least one oil outlet comprises a plurality of oil outlets arranged to pass through the first end wall adjacent to the first end of the truncated cone wall.

[0091] According to any of the preceding clauses, the air-oil separation system wherein the first end wall includes at least one first end wall coolant flow passage therein, the at least one first end wall coolant flow passage being in fluid communication with the inlet coolant flow passage of each air-oil inlet and in fluid communication with the at least one outer shell coolant flow passage of the truncated cone wall.

[0092] According to any of the preceding clauses, the air-oil separation system wherein the second end wall includes at least one second end wall coolant flow passage therein, the at least one second end wall coolant flow passage being in fluid communication with the at least one outer shell wall coolant flow passage.

[0093] According to any of the preceding clauses, the air-oil separation system wherein the separator shaft includes a shaft coolant inlet portion and a shaft coolant outlet portion, the shaft coolant inlet portion being in fluid communication with the at least one first endwall coolant flow passage to provide the coolant flow thereto, and the shaft coolant outlet portion being in fluid communication with the at least one second endwall coolant flow passage to receive the coolant flow from the at least one second endwall coolant flow passage.

[0094] According to any of the preceding clauses, the air-oil separation system further includes at least one air outlet passage fluidly connected to the separation chamber of the air-oil separator and arranged to provide a flow of the air components exiting the separation chamber.

[0095] According to the air-oil separation system described in the preceding clause, in operation, (i) the air-oil separator is driven to rotate by the separator shaft; (ii) the air-oil mixture flows from the oil sump through the air-oil inlet portion into the separation chamber, and the air-oil mixture is cooled by the coolant flowing through the inlet coolant flow passage; (iii) the air-oil mixture swirls in the separation chamber to separate the air-oil mixture, thereby obtaining an oil component and an air component; (iv) the oil component flows along the surface of the separator housing to at least one oil outlet, and the oil component is further cooled by the coolant flowing through the at least one housing wall coolant flow passage; (v) the oil component flows through the at least one oil outlet to exit the separation chamber and flow into the oil sump; and (vi) the air component flows through the at least one air outlet passage to exit the separation chamber.

[0096] A gas turbine engine includes: a high-pressure spool including a high-pressure compressor and a high-pressure turbine, the high-pressure compressor and the high-pressure turbine being connected via a high-pressure shaft and supported by a high-pressure shaft bearing; a low-pressure spool including a low-pressure compressor and a low-pressure turbine, the low-pressure compressor and the low-pressure turbine being connected via a low-pressure shaft and supported by a low-pressure bearing; at least one oil pan for providing oil lubrication to at least one of the high-pressure bearing and the low-pressure bearing; and at least one air-oil separation system disposed within the at least one oil pan, the at least one air-oil separation system including: an air-oil separator arranged to separate an air-oil mixture into an oil component and an air component; at least one An air-oil inlet portion, the at least one air-oil inlet portion being arranged to feed the air-oil mixture from the oil sump into the separation chamber of the air-oil separator, the air-oil inlet portion including an inlet heat exchanger portion having an inlet coolant flow passage arranged to provide coolant flowing therethrough to cool the air-oil mixture entering the air-oil inlet portion; at least one oil outlet, the at least one oil outlet being arranged to provide the oil component flowing from the separation chamber of the air-oil separator to the oil sump; and an air outlet, the air outlet being arranged to provide the air component flowing out of the separation chamber of the air-oil separator.

[0097] The gas turbine engine according to any of the preceding clauses, wherein the coolant is at least one of air, fuel or oil.

[0098] According to any of the preceding clauses, the gas turbine engine wherein the inlet heat exchanger is arranged as a counter-flow heat exchanger, wherein the air-oil mixture flows in a first direction and the coolant flows in a second direction.

[0099] According to any of the preceding clauses, the gas turbine engine includes a counter-flow heat exchanger comprising a serpentine coolant flow path and a serpentine oil flow path.

[0100] According to any of the preceding clauses, the gas turbine engine wherein the counter-flow heat exchanger is configured as any one of a tubular heat exchanger, a plate heat exchanger, a finned heat exchanger, or an integral unit heat exchanger.

[0101] According to any of the preceding clauses, the gas turbine engine, wherein the air-oil separator includes (a) a separator housing, (b) a first end wall, (c) a second end wall, and (d) a separator shaft, and the separation chamber is defined between the separator housing, the first end wall, and the second end wall.

[0102] According to any of the preceding clauses, the gas turbine engine wherein the air-oil separator is arranged to be rotatably driven by a separator shaft, and the rotatable drive of the air-oil separator causes oil components to flow along the inner surface of the separator housing and out from at least one oil outlet into the oil pan.

[0103] According to any of the preceding clauses of the gas turbine engine, wherein the air-oil separator further includes at least one wire mesh element extending from the air-oil inlet portion to the separation chamber, the at least one wire mesh element being arranged to atomize the air-oil mixture within the separation chamber.

[0104] According to any of the preceding clauses, the gas turbine engine comprises: (i) an outer first end wall portion fixedly connected to the separator housing and an inner first end wall portion fixedly connected to a support structure for mounting the air-oil separation system; (ii) a second end wall fixedly connected to the separator housing and the separator shaft, the separator shaft being arranged to rotatably drive the second end wall, the separator housing, and the outer first end wall portion about a longitudinal centerline axis of the air-oil separation system, and the inner first end wall portion being fixedly mounted relative to the separator shaft, the at least one air-oil inlet portion being arranged to extend through the inner first end wall portion, and the at least one oil outlet portion being arranged to extend through the outer first end wall portion.

[0105] According to any of the preceding claims, in the gas turbine engine, the separator housing includes a truncated cone wall extending about a longitudinal centerline axis of the separator housing, a first end wall disposed at a first end of the truncated cone wall and including an outer first end wall portion and an inner first end wall portion, and a second end wall disposed at a second end of the truncated cone wall, the inner first end wall portion being fixedly mounted relative to the separator shaft, and the outer first end wall portion being rotatably connected to the inner first end wall portion, and the at least one air-oil inlet portion being connected to the inner first end wall portion.

[0106] The gas turbine engine according to any of the preceding clauses is characterized in that the air-oil separation system further includes a fixed cyclone separator extending from the air-oil inlet portion into the separation chamber.

[0107] The gas turbine engine according to any of the preceding clauses is characterized in that the stationary cyclone includes a plurality of blades arranged to introduce cyclones into the air-oil mixture in the separation chamber.

[0108] The gas turbine engine according to any of the preceding claims is characterized in that the separator housing includes a truncated cone wall, the truncated cone wall including at least one housing wall coolant flow passage within the truncated cone wall and arranged to provide coolant through therein to cool the air-oil mixture in the separator chamber.

[0109] The gas turbine engine according to any of the preceding clauses is characterized in that the at least one casing wall coolant flow passage includes a plurality of casing coolant flow channels.

[0110] The gas turbine engine according to any of the preceding claims is characterized in that the truncated cone wall includes an outer wall of the separator housing and an inner wall of the separator housing, the at least one housing wall coolant flow passage is defined between the outer wall of the separator housing and the inner wall of the separator housing, and a plurality of heat exchange components are arranged in the at least one housing wall coolant flow passage.

[0111] In the gas turbine engine according to any of the preceding clauses, the plurality of heat exchanger components are heat exchange columns connected to the outer wall of the separator housing and to the inner wall of the separator housing.

[0112] According to any of the preceding clauses, in a gas turbine engine, a plurality of heat exchange columns are spaced apart from each other in the circumferential direction relative to the longitudinal centerline axis within the coolant flow passage of a single outer casing wall.

[0113] In the gas turbine engine according to any of the preceding clauses, the plurality of heat exchanger components are heat exchange blocks (or units) connected to the outer wall of the separator housing and to the inner wall of the separator housing.

[0114] According to any of the preceding clauses, in a gas turbine engine, each of the plurality of heat exchange blocks includes a coolant flow passage therethrough.

[0115] According to any of the preceding clauses, in a gas turbine engine, a plurality of heat exchange columns are spaced apart from each other in the circumferential direction relative to the longitudinal centerline axis within the coolant flow passage of a single outer casing wall.

[0116] The gas turbine engine according to any of the preceding clauses, wherein the outer casing coolant flow passage includes a plurality of outer casing coolant flow channels.

[0117] According to any of the preceding clauses, the gas turbine engine, wherein the plurality of casing coolant flow channels includes a plurality of inner casing coolant flow channels and a plurality of outer casing coolant flow channels.

[0118] According to any of the preceding clauses, in a gas turbine engine, the truncated cone wall includes a blade structure on the inner surface of the truncated cone wall, the blade structure being arranged to generate swirl in the air-oil mixture within the separation chamber.

[0119] According to any of the preceding clauses, in the gas turbine engine, the first end wall is disposed at a first end of the truncated cone wall, the second end wall is disposed at a second end of the truncated cone wall, and the at least one air-oil inlet portion and the at least one oil outlet are disposed through the first end wall.

[0120] The gas turbine engine according to any of the preceding clauses, wherein the first end wall has a first diameter and the second end wall has a second diameter smaller than the first diameter, and the at least one oil outlet comprises a plurality of oil outlets arranged to pass through the first end wall adjacent to the first end of the truncated cone wall.

[0121] According to any of the preceding clauses, in the gas turbine engine, wherein the first end wall includes at least one first end wall coolant flow passage therein, the at least one first end wall coolant flow passage being in fluid communication with the inlet coolant flow passage of each air-oil inlet and in fluid communication with the at least one outer shell coolant flow passage of the truncated cone wall.

[0122] According to any of the preceding clauses, in the gas turbine engine, the second end wall includes at least one second end wall coolant flow passage therein, the at least one second end wall coolant flow passage being in fluid communication with the at least one outer casing wall coolant flow passage.

[0123] According to any of the preceding clauses, the gas turbine engine wherein the separator shaft includes a shaft coolant inlet portion and a shaft coolant outlet portion, the shaft coolant inlet portion being in fluid communication with the at least one first endwall coolant flow passage to provide the coolant flow thereto, and the shaft coolant outlet portion being in fluid communication with the at least one second endwall coolant flow passage to receive the coolant flow from the at least one second endwall coolant flow passage.

[0124] According to any of the preceding clauses, the gas turbine engine, wherein the separator shaft further includes at least one air outlet passage fluidly connected to the separation chamber of the air-oil separator and arranged to provide a flow of the air components exiting the separation chamber.

[0125] According to any of the preceding clauses, in operation, (i) the air-oil separator is driven to rotate by the separator shaft; (ii) the air-oil mixture flows from the oil sump through the air-oil inlet portion into the separation chamber, and the air-oil mixture is cooled by the coolant flowing through the inlet coolant flow passage; (iii) the air-oil mixture swirls in the separation chamber to separate the air-oil mixture, thereby obtaining an oil component and an air component; (iv) the oil component flows along the surface of the separator housing to at least one oil outlet, and the oil component is further cooled by the coolant flowing through the at least one housing wall coolant flow passage; (v) the oil component flows through the at least one oil outlet to exit the separation chamber and flow into the oil sump; and (vi) the air component flows through the at least one air outlet passage to exit the separation chamber.

[0126] A gas turbine engine includes a high-pressure spool comprising a high-pressure compressor and a high-pressure turbine connected via a high-pressure shaft and supported by a high-pressure shaft bearing; a low-pressure spool comprising a low-pressure compressor and a low-pressure turbine connected via a low-pressure shaft and supported by a low-pressure bearing; a high-pressure oil sump for providing oil lubrication to the high-pressure bearing; a low-pressure oil sump for providing oil lubrication to the low-pressure bearing; an accessory gearbox driven by the high-pressure spool; and a main oil sump that provides oil lubrication to and is driven by the accessory gearbox and is fluidly connected to both the high-pressure and low-pressure oil sumps. The main oil sump includes an air-oil separation system comprising an air-oil separator. The separator is arranged to separate an air-oil mixture into an oil component and an air component; at least one air-oil inlet portion, the at least one air-oil inlet portion being arranged to input the air-oil mixture from the oil sump into the separation chamber of the air-oil separator, the air-oil inlet portion including an inlet heat exchanger portion having an inlet coolant flow passage arranged to provide a coolant flow therethrough to cool the air-oil mixture input into the air-oil inlet portion; at least one oil outlet, the at least one oil outlet being arranged to provide the oil component flowing from the separation chamber of the air-oil separator to the oil sump; and an air outlet, the air outlet being arranged to provide the air component flowing out of the separation chamber of the air-oil separator.

[0127] The gas turbine engine according to any of the preceding clauses, wherein the coolant is at least one of air, fuel or oil.

[0128] According to any of the preceding clauses, the gas turbine engine, wherein the air-oil separator includes (a) a separator housing, (b) a first end wall, (c) a second end wall, and (d) a separator shaft, and the separation chamber is defined between the separator housing, the first end wall, and the second end wall.

[0129] According to any of the preceding clauses, the gas turbine engine wherein the air-oil separator is arranged to be rotatably driven by a separator shaft, and the rotatable drive of the air-oil separator causes oil components to flow along the inner surface of the separator housing and out from at least one oil outlet into the oil pan.

[0130] According to any of the preceding clauses of the gas turbine engine, wherein the air-oil separator further includes at least one wire mesh element extending from the air-oil inlet portion to the separation chamber, the at least one wire mesh element being arranged to atomize the air-oil mixture within the separation chamber.

[0131] According to any of the preceding clauses, the gas turbine engine comprises: (i) an outer first end wall portion fixedly connected to the separator housing and an inner first end wall portion fixedly connected to a support structure for mounting the air-oil separation system; (ii) a second end wall fixedly connected to the separator housing and the separator shaft, the separator shaft being arranged to rotatably drive the second end wall, the separator housing, and the outer first end wall portion about a longitudinal centerline axis of the air-oil separation system, and the inner first end wall portion being fixedly mounted relative to the separator shaft, the at least one air-oil inlet portion being arranged to extend through the inner first end wall portion, and the at least one oil outlet portion being arranged to extend through the outer first end wall portion.

[0132] According to any of the preceding claims, in the gas turbine engine, the separator housing includes a truncated cone wall extending about a longitudinal centerline axis of the separator housing, a first end wall disposed at a first end of the truncated cone wall and including an outer first end wall portion and an inner first end wall portion, and a second end wall disposed at a second end of the truncated cone wall, the inner first end wall portion being fixedly mounted relative to the separator shaft, and the outer first end wall portion being rotatably connected to the inner first end wall portion, and the at least one air-oil inlet portion being connected to the inner first end wall portion.

[0133] The gas turbine engine according to any of the preceding clauses is characterized in that the air-oil separation system further includes a fixed cyclone separator extending from the air-oil inlet portion into the separation chamber.

[0134] The gas turbine engine according to any of the preceding clauses is characterized in that the stationary cyclone includes a plurality of blades arranged to introduce cyclones into the air-oil mixture in the separation chamber.

[0135] The gas turbine engine according to any of the preceding claims is characterized in that the separator housing includes a truncated cone wall, the truncated cone wall including at least one housing wall coolant flow passage within the truncated cone wall and arranged to provide coolant through therein to cool the air-oil mixture in the separator chamber.

[0136] The gas turbine engine according to any of the preceding clauses is characterized in that the at least one casing wall coolant flow passage includes a plurality of casing coolant flow channels.

[0137] According to any of the preceding clauses, the gas turbine engine includes a separator housing outer wall and a separator housing inner wall, at least one housing coolant flow passage is defined between the separator housing outer wall and the separator housing inner wall, and a plurality of heat exchanger components are arranged within the at least one housing coolant flow passage.

[0138] According to any of the preceding clauses, in a gas turbine engine, the truncated cone wall includes a blade structure on the inner surface of the truncated cone wall, the blade structure being arranged to generate swirl in the air-oil mixture within the separation chamber.

[0139] According to any of the preceding clauses, in the gas turbine engine, the first end wall is disposed at a first end of the truncated cone wall, the second end wall is disposed at a second end of the truncated cone wall, and the at least one air-oil inlet portion and the at least one oil outlet are disposed through the first end wall.

[0140] The gas turbine engine according to any of the preceding clauses, wherein the first end wall has a first diameter and the second end wall has a second diameter smaller than the first diameter, and the at least one oil outlet comprises a plurality of oil outlets arranged to pass through the first end wall adjacent to the first end of the truncated cone wall.

[0141] According to any of the preceding clauses, in the gas turbine engine, wherein the first end wall includes at least one first end wall coolant flow passage therein, the at least one first end wall coolant flow passage being in fluid communication with the inlet coolant flow passage of each air-oil inlet and in fluid communication with the at least one outer shell coolant flow passage of the truncated cone wall.

[0142] According to any of the preceding clauses, in the gas turbine engine, the second end wall includes at least one second end wall coolant flow passage therein, the at least one second end wall coolant flow passage being in fluid communication with the at least one outer casing wall coolant flow passage.

[0143] According to any of the preceding clauses, the gas turbine engine wherein the separator shaft includes a shaft coolant inlet portion and a shaft coolant outlet portion, the shaft coolant inlet portion being in fluid communication with the at least one first endwall coolant flow passage to provide the coolant flow thereto, and the shaft coolant outlet portion being in fluid communication with the at least one second endwall coolant flow passage to receive the coolant flow from the at least one second endwall coolant flow passage.

[0144] According to any of the preceding clauses, the gas turbine engine, wherein the separator shaft further includes at least one air outlet passage that is in fluid communication with the separation chamber of the air-oil separator and is arranged to provide a flow of the air components exiting the separation chamber.

[0145] According to any of the preceding clauses, in operation, (i) the air-oil separator is driven to rotate by the separator shaft; (ii) the air-oil mixture flows from the oil sump through the air-oil inlet portion into the separation chamber, and the air-oil mixture is cooled by the coolant flowing through the inlet coolant flow passage; (iii) the air-oil mixture swirls in the separation chamber to separate the air-oil mixture, thereby obtaining an oil component and an air component; (iv) the oil component flows along the surface of the separator housing to at least one oil outlet, and the oil component is further cooled by the coolant flowing through the at least one housing wall coolant flow passage; (v) the oil component flows through the at least one oil outlet to exit the separation chamber and flow into the oil sump; and (vi) the air component flows through the at least one air outlet passage to exit the separation chamber.

[0146] While the foregoing description pertains to some exemplary embodiments of this disclosure, those skilled in the art will understand that other variations and modifications can be made without departing from this disclosure. Furthermore, even if not explicitly mentioned above, features associated with one embodiment of this disclosure can be used in conjunction with other embodiments.

Claims

1. An air-oil separation system for an oil pan in a gas turbine engine, characterized in that, The air-oil separation system includes: An air-oil separator, wherein the air-oil separator is arranged to separate an air-oil mixture into an oil component and an air component; At least one air-oil inlet portion, the at least one air-oil inlet portion being arranged to input the air-oil mixture from the oil sump into the separation chamber of the air-oil separator, the air-oil inlet portion including an inlet heat exchanger portion having an inlet coolant flow passage arranged to provide a coolant flow therethrough to cool the air-oil mixture input into the air-oil inlet portion; At least one oil outlet, said at least one oil outlet being arranged to provide the oil components flowing from the separation chamber of the air-oil separator to the oil sump; and An air outlet is provided to supply the air components flowing out of the separation chamber of the air-oil separator.

2. The air-oil separation system according to claim 1, characterized in that, The coolant is at least one of air, fuel or oil.

3. The air-oil separation system according to claim 1, characterized in that, The air-oil separator includes (a) a separator housing, (b) a first end wall, (c) a second end wall, and (d) a separator shaft, wherein the separation chamber is defined between the separator housing, the first end wall, and the second end wall.

4. The air-oil separation system according to claim 3, characterized in that, The air-oil separator is arranged to be rotatably driven by the separator shaft, and the rotational drive of the air-oil separator causes the oil components to flow along the inner surface of the separator housing and out from the at least one oil outlet into the oil pan.

5. The air-oil separation system according to claim 3, characterized in that, The air-oil separator further includes at least one wire mesh element extending from the air-oil inlet portion to the separation chamber, the at least one wire mesh element being arranged to atomize the air-oil mixture in the separation chamber.

6. The air-oil separation system according to claim 3, characterized in that, in: (i) The first end wall includes an outer first end wall portion fixedly connected to the separator housing and an inner first end wall portion fixedly connected to a support structure for mounting the air-oil separation system; (ii) The second end wall is fixedly connected to the separator housing and the separator shaft, the separator shaft being arranged to rotatably drive the second end wall, the separator housing, and the outer first end wall portion about the longitudinal centerline axis of the air-oil separation system, and the inner first end wall portion being fixedly mounted relative to the separator shaft, the at least one air-oil inlet portion being arranged to extend through the inner first end wall portion, and the at least one oil outlet portion being arranged to extend through the outer first end wall portion.

7. The air-oil separation system according to claim 3, characterized in that, The separator housing includes a truncated cone wall extending around a longitudinal centerline axis of the separator housing. A first end wall is disposed at a first end of the truncated cone wall and includes an outer first end wall portion and an inner first end wall portion. A second end wall is disposed at a second end of the truncated cone wall. The inner first end wall portion is fixedly mounted relative to the separator shaft. The outer first end wall portion is rotatably connected to the inner first end wall portion. The at least one air-oil inlet portion is connected to the inner first end wall portion.

8. The air-oil separation system according to claim 7, characterized in that, The air-oil separation system further includes a fixed cyclone separator extending from the air-oil inlet portion into the separation chamber.

9. The air-oil separation system according to claim 8, characterized in that, The stationary cyclone separator includes a plurality of blades arranged to introduce cyclones into the air-oil mixture within the separation chamber.

10. The air-oil separation system according to claim 3, characterized in that, The separator housing includes a truncated cone wall, which includes at least one housing wall coolant flow passage within the truncated cone wall and is arranged to provide a coolant flow through it, thereby providing cooling to the air-oil mixture within the separation chamber.

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