Airfoil Insert System for Aft Cooling and Maintenance
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Solution Overview
Problem
Existing rotary machine airfoil cooling systems with integrated impingement inserts are difficult to replace and have limited insertion depth, leading to ineffective cooling of internal surfaces, especially in areas where the plenum inlet does not extend over the aft portion due to dimensional constraints.
Innovation Solution
A two-insert system where a second insert is inserted radially through the plenum inlet and a first insert is nested within it, allowing the first insert to extend aftward into the airfoil's aft portion, providing effective impingement cooling and facilitating easy installation and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a single removable insert is used with limited insertion depth, then ease of replacement is improved, but cooling effectiveness in aft portions deteriorates
Solution Approach 1:
The cooling insert is divided into two separate inserts: a first insert with impingement openings for cooling the aft portion of the airfoil, and a second insert with a plenum chamber for receiving cooling fluid. This segmentation allows each insert to be optimized for its specific function while maintaining removability for ease of replacement.
Solution Approach 2:
The first insert is positioned within the second insert, with the first insert extending through the aft opening of the second insert into the aft portion of the airfoil. This nested configuration allows the cooling system to reach deeper into the airfoil structure while maintaining the ability to remove and replace the inserts independently.
2Reliability
If integrated components with impingement openings are used, then cooling effectiveness is improved, but ease of replacement deteriorates
Solution Approach 1:
The cooling system is segmented into removable inserts rather than being integrated into the airfoil structure. The first and second inserts can be independently removed from the airfoil, facilitating easy replacement while maintaining the impingement cooling functionality.
Solution Approach 2:
The impingement cooling functionality is extracted from the airfoil structure and implemented as separate removable inserts. This extraction allows the cooling components to be independently maintained and replaced without affecting the airfoil structure itself.
3Ease of manufacture
If plenum inlet is constrained by dimensional limits, then manufacturing simplicity is improved, but cooling fluid reach deteriorates
Solution Approach 1:
The cooling fluid delivery system utilizes multiple dimensions: the second insert receives cooling fluid radially through the plenum inlet, stores it in the plenum chamber, and the first insert extends axially through the aft opening to deliver cooling fluid to the aft portion. This multi-dimensional approach allows extended reach without increasing the radial footprint of the plenum inlet.
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 system enables effective impingement cooling of previously under-cooled aft portions, reducing thermal degradation and increasing the longevity of airfoil components, while allowing for easy maintenance and repair by extending cooling fluid reach beyond the initial plenum inlet limits.
Implementation Method 1
These components or inserts allow the cooling fluid channeled into the plenum through the plenum inlet opening to be directed by the impingement openings to impingement upon the internal surfaces of the airfoil, thus increasing the cooling of the internal components of the airfoil
Implementation Method 2
a cooling fluid, such as bleed air extracted from a compressor or steam, is forced through plenums defined within the airfoil
Data Source
AI summary
An insert system for an airfoil plenum includes a first insert and a second insert that include a plurality of impingement openings defined therein. The first insert includes a forward-facing inlet opening. The second insert includes a neck portion having a radial-facing inlet opening, an aft opening, and a cavity in flow communication between the radial-facing inlet opening and the aft opening. The second insert is sized for insertion into the plenum radially through a plenum inlet such that the neck portion is positioned in the plenum inlet. The first insert is sized for insertion into the second insert radially through the radial-facing inlet opening. When the neck portion is positioned in the plenum inlet, the first insert is moveable aftward through the aft opening into an installed position such that the forward-facing inlet opening opens into the cavity.