3D Mixer Vanes for Gas Turbine Combustor Fuel-Air Mixing
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Solution Overview
Problem
Conventional mixer designs for TAPS fuel nozzles in gas turbine engines have 2-dimensional vane designs with constant shapes, which limit fuel-air mixing efficiency, autoignition, and durability, particularly in staged combustors aiming for low emissions and high engine output.
Innovation Solution
The introduction of a mixer assembly with 3-dimensional shaped vanes that have varying lengths, widths, thicknesses, curvatures, and twists, allowing for non-uniform shapes to enhance airflow characteristics and improve fuel-air mixing and durability, specifically in both main and pilot stages of TAPS fuel nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional 2-dimensional mixer vane designs with constant shapes are used, then manufacturing simplicity is maintained, but fuel-air mixing efficiency and autoignition performance are limited
Solution Approach 1:
The patent transitions from conventional 2-dimensional mixer vane designs to 3-dimensional shaped vanes with varying cross-sections along their length. This dimensional change enables the vanes to create more complex airflow patterns including secondary flows and enhanced turbulence, thereby improving fuel-air mixing efficiency while maintaining manufacturability through modern manufacturing processes
2Productivity
If 3-dimensional shaped mixer vanes with varying lengths, widths, and twists are introduced, then fuel-air mixing and autoignition are enhanced, but device complexity increases
Solution Approach 1:
The patent applies local quality by varying the cross-sectional dimensions (width, thickness) and twist angles of mixer vanes at different locations along their length. Each section of the vane is optimized locally to create specific airflow characteristics - for example, varying twist angles to control swirl intensity at different radial positions, which enhances fuel-air mixing efficiency
Solution Approach 2:
The patent systematically varies geometric parameters including length, width, thickness, curvature, and twist along the vane body. These parameter changes are designed to optimize airflow velocity profiles and create beneficial turbulence patterns that enhance mixing and autoignition performance
3Device complexity
If conventional constant-shape mixer vanes are used, then structural simplicity is maintained, but durability and engine output performance are limited
Solution Approach 1:
The patent introduces 3-dimensional shaping with varying cross-sections that can be optimized for durability. The thicker sections can be positioned in high-stress areas to resist thermal and mechanical loads, while maintaining overall structural integrity. This dimensional optimization allows the vanes to withstand harsh combustor conditions longer, improving durability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The 3-dimensional mixer vanes optimize fuel-air mixing and autoignition performance, enhancing the overall efficiency and durability of the fuel nozzle assembly by tailoring airflow velocity profiles, thereby improving engine output and reducing emissions.
Implementation Method 1
each having a 3-dimensional shape defined by the length, width, thickness, cross-sectional area, curvature, and twist of the body portion
Implementation Method 2
enhance fuel-air mixing
Implementation Method 3
tailoring airflow velocity profiles, thereby improving engine output
Data Source
AI summary
A mixer assembly having a plurality of mixer vanes, each of the plurality of mixer vanes having a first end, a second end, and a body portion extending between the first end and the second end, the body portion having a length, a width, a thickness, a cross-sectional area, a curvature, and a twist, wherein each of the plurality of mixer vanes has a 3-dimensional shape defined by the length, width, thickness, cross-sectional area, curvature, and twist of the body portion, and wherein at least one of the plurality of mixer vanes has a non-uniform 3-dimensional shape.