Active Synchronization Ring for Gas Turbine Vane Control

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Solution Overview

Problem

Gas turbine engines face vane angle errors due to synchronization ring distortion, which existing solutions attempt to mitigate by stiffening the ring, resulting in increased weight and inefficiency.

Innovation Solution

An active synchronization ring system is introduced, featuring micro-actuators coupled to the synchronization ring to counteract distortion, with strain sensors measuring ring deformation and controllers commanding micro-actuators to apply bending moments and correct vane angles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the synchronization ring is stiffened to reduce distortion, then vane angle accuracy is improved, but the weight of the ring increases

Engineering Contradiction:

Improvevane angle accuracyVSAvoidsynchronization ring weight

Core Design Contradiction:

Measurement precisionVSWeight of moving object

Solution Approach 1:

The patent applies active control to the synchronization ring, transforming it from a static passive structure to a dynamic active structure. Micro-actuators are integrated into the ring to actively counteract distortion in real-time, allowing the ring to maintain accuracy without requiring excessive stiffness and weight. This dynamic approach enables the ring to adapt its shape actively rather than relying on passive structural rigidity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the physical state and properties of the synchronization ring by incorporating micro-actuators that can alter the ring's shape and stiffness characteristics dynamically. Instead of maintaining constant high stiffness through material selection or geometric design, the system uses actuators to change the effective stiffness and shape parameters as needed, reducing the need for heavy structural design.

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If more actuators are added to control the synchronization ring, then vane angle control precision is improved, but the device complexity increases

Engineering Contradiction:

Improvevane angle control precisionVSAvoidactuator system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent segments the control function by integrating multiple small micro-actuators directly into the synchronization ring structure, rather than using one or two large external actuators. This segmentation allows distributed control of different sections of the ring, achieving high precision while keeping each individual actuator simple and manageable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent merges the micro-actuators with the synchronization ring structure itself, making them integral parts of the ring rather than separate external components. This integration reduces the overall system complexity by combining the control elements with the structural element they control, eliminating the need for separate mounting mechanisms and control linkages.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If the synchronization ring is made more rigid to counteract distortion, then manufacturing precision is improved, but the ease of manufacture decreases

Engineering Contradiction:

Improvering distortion controlVSAvoidsynchronization ring fabrication

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent employs composite construction by integrating micro-actuators into the synchronization ring, creating a composite structure that combines the ring material with actuator elements. This allows the base ring to be manufactured from standard materials with normal manufacturing processes, while the active control capability is added through the integrated actuators, maintaining ease of manufacture while achieving high precision.

Inventive Principle:

Principle #40Composite materials

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

This approach allows for precise correction of vane angle errors, enhancing the accuracy and efficiency of gas turbine performance without the need for excessive weight or additional actuators, thereby improving the engine's operational range.

Implementation Method 1

strain sensors measuring ring deformation

Methodology Applied

Scientific EffectStrain measurement:

Implementation Method 2

controllers commanding micro-actuators to apply bending moments

Methodology Applied

Scientific EffectBending moment application:

Data Source

PatentUS10851666B2Active synchronizing ring

Publication Date: 2020.12.01 ROLLS ROYCE NORTH AMERICAN TECHNOLOGIES INC

AI summary

An improved system, apparatus and method for controlling vane angles in a gas turbine engine, and more specifically, for correcting vane angle error in a gas turbine engine. An active synchronization ring comprises a plurality of micro-actuators coupled to the synchronization ring to correct distortion in the synchronization ring. The micro-actuators apply a bending moment to the synchronization ring to cancel or compensate for synchronization ring distortion. The micro-actuators may be controlled open loop or closed loop. Strain sensors measure ring distortion and provide signals to the controller for closed loop control.