Blade Tip Clearance Sensor Mounting With Integrated Probe Cooling
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Solution Overview
Problem
Existing blade tip clearance sensors in gas turbines face challenges in maintaining stable operation and response reliability under harsh environments such as high temperature, high pressure, and high vibration, due to instability in probe fixation.
Innovation Solution
A blade tip clearance sensor design featuring a bushing portion made of Inconel alloy, a washer portion of stainless steel, a flange portion with cooling holes, a sensor probe with a cooling channel, and a locking screw, all configured to securely mount and cool the sensor probe, ensuring stability and reliability in harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional probe fixation method is used, then the sensor can be installed, but the probe becomes unstable under high temperature, high pressure, and high vibration conditions
Solution Approach 1:
The probe fixation system uses a composite structure combining Inconel alloy bushing portion (high temperature and corrosion resistant) with stainless steel washer and locking components. This composite material approach provides both thermal stability and mechanical strength needed to resist high temperature, high pressure, and high vibration conditions while maintaining reliable probe fixation.
Solution Approach 2:
The fixation system is divided into multiple functional segments: the bushing portion (provides structural support and cooling), the washer portion (provides mounting surface), the flange portion (provides additional support), and the locking screw (provides secure fastening). This segmentation allows each component to be optimized for its specific function while collectively providing stable probe fixation under harsh conditions.
2Measurement precision
If the sensor probe is exposed to harsh operating environments, then it can monitor blade tip clearance, but operation stability and response reliability deteriorate
Solution Approach 1:
The bushing portion acts as an intermediary between the harsh operating environment and the sensor probe. It provides a protected interface that includes cooling channels to reduce thermal exposure and a stable mechanical interface to reduce vibration and pressure effects, thereby maintaining measurement precision while improving operation stability and response reliability.
Solution Approach 2:
The cooling channels in the bushing portion provide beforehand cushioning by pre-cooling the sensor probe before it is exposed to high temperature environments. This proactive thermal management prevents excessive heating that would cause drift in measurements and maintain reliable operation throughout the sensor's service life.
3Reliability
If the sensor probe is not cooled, then the structure can be simple, but the sensor cannot operate stably under high temperature conditions
Solution Approach 1:
The cooling function is merged with the structural bushing portion rather than being a separate system. The cooling channels are integrated into the bushing's wall structure, allowing the same component to provide both mechanical support and thermal management. This merging provides reliable sensor operation under high temperature conditions while minimizing additional structural complexity.
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 sensor probe is stably fixed and cooled, maintaining operation stability and response reliability under high temperature, high pressure, and high vibrational environments, enhancing the efficiency and safety of the gas turbine by accurately monitoring blade tip clearance.
Implementation Method 1
a flange portion provided on an upper surface of the washer portion and provided with a plurality of first cooling holes formed around the second hollow portion; a sensor probe inserted into the first hollow portion and the second hollow portion, the sensor probe having a cooling channel
Data Source
AI summary
Proposed are a blade tip clearance sensor and a gas turbine including the same. The blade tip clearance sensor includes a bushing portion which is fixed to a ring segment mounted on a turbine casing that accommodates a turbine blade therein and which has an internal space, a washer portion mounted on a lower portion of the internal space and provided with a first hollow portion, a flange portion provided on an upper surface of the washer portion and provided with a second hollow portion, a sensor probe which is inserted into the first and second hollow portions and which has a sensor cable, a spacer provided on an upper surface of the flange portion and configured to accommodate the sensor probe therein, and a locking screw which is provided on an upper surface of the spacer and which has a thread engaged with a thread of the bushing portion.