High Pressure Compressor Rotor Stack Thermal Fatigue Management
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Solution Overview
Problem
The existing gas turbine engines experience thermal mechanical fatigue due to increasing air temperature in the compressor section, which causes component expansion and potential damage, necessitating improved thermal management.
Innovation Solution
A high-pressure compressor rotor stack design with a bore basket internal passage, fluid communication through hub structures, anti-vortex cavities, and seals to control fluid flow and temperature, reducing thermal mechanical fatigue by managing air flow and temperature distribution across rotor stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If air is compressed in the compressor section, then pressure and temperature of air increase, but thermal mechanical fatigue of components increases due to warming
Solution Approach 1:
The patent extracts hot air from the compressor section and redirects it through a separate passage system away from the rotor stack. The bore basket includes internal passages that channel the warmed air away from direct contact with rotor components, preventing thermal accumulation and reducing thermal mechanical fatigue while preserving compression work.
Solution Approach 2:
The patent introduces an intermediary fluid flow path through the bore basket passages that acts as a mediator between the compressed air and the rotor stack. This intermediate passage system controls the thermal interaction by directing air flow in a way that accomplishes compression objectives while minimizing harmful thermal effects on rotor components.
2Reliability
If thermal management is improved to reduce thermal mechanical fatigue, then component durability increases, but device complexity increases due to additional passages and seals
Solution Approach 1:
The patent merges the thermal management function with the existing bore basket structure. The internal passages are integrated into the bore basket itself rather than being separate components, and the seals are incorporated into the existing rotor stage assemblies. This integration achieves effective thermal management while minimizing additional structural complexity.
Solution Approach 2:
The bore basket structure serves multiple functions: it provides structural support for the rotor stages, defines the compression flow path, and simultaneously acts as a thermal management system through its internal passages. This multi-functionality reduces the need for separate dedicated cooling components, thereby limiting the increase in device 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 design effectively reduces thermal mechanical fatigue by controlling air flow and temperature across rotor stages, enhancing the durability and performance of compressor components.
Implementation Method 1
an anti-vortex cavity is located axially between the forward rotor bore and the aft rotor bore, the anti-vortex cavity comprising at least one anti-vortex tube configured to de-swirl a flow of air
Implementation Method 2
a first fluid inlet to a forward rotor bore extends through the forward hub structure... a first fluid outlet from the forward rotor bore... heating at least one forward rotor disk in the forward rotor bore with the first fluid entering the forward rotor bore
Data Source
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AI summary
A high pressure compressor rotor stack (60) includes a bore basket (62) that includes a bore basket internal passage (84). A first plurality of rotor stages (66) at least partially defines a forward rotor bore (72) with a forward hub structure (64) and the bore basket (62). A second plurality of rotor stages (68) at least partially defines an aft rotor bore (102) with an aft hub structure (70) and the bore basket (62). A method of directing fluid through a high pressure turbine rotor stack (60) comprises the steps of: directing a first fluid through a forward rotor bore (72), wherein a fluid inlet (80) to the forward rotor bore (72) extends through a forward hub structure (64) and an outlet (88) of the forward rotor bore (72) is in fluid communication with a bearing compartment (90); directing a second fluid through an anti-vortex cavity (94); and directing a third fluid through an aft rotor bore (102) in an upstream direction.