Electromechanical Lubricant Flow Valve for Gas Turbine Load Control
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Solution Overview
Problem
Existing lubricant supply systems in gas turbine engines face inefficiencies due to the use of high-pressure, high-temperature air from the compressor, which can cause the mechanical valve to jam and reduce lubricant viscosity, leading to excessive lubricant flow and decreased system efficiency.
Innovation Solution
A lubricant supply system utilizing an electromechanical actuator and control valve that regulates lubricant flow based on compressor pressure, eliminating the need for high-pressure, high-temperature air, and incorporating a flow chamber with specific orifices to control lubricant flow effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a pneumatically actuated flow reduction valve is used to regulate lubricant flow, then lubricant flow can be reduced as a function of engine load, but the mechanical valve piston can become jammed due to excessive heating and friction
Solution Approach 1:
The patent replaces the pneumatic actuation system with an electronic control system. Instead of using compressed air to actuate the valve piston, the invention employs an electronic control valve with an electronic actuator that receives commands from a controller based on engine operating parameters. This substitution eliminates the mechanical jamming issues caused by high-temperature air and friction in the pneumatic system.
Solution Approach 2:
The invention changes the actuation parameter from pneumatic pressure to electronic control signals. The control valve is actuated by electronic commands that adjust the valve position based on measured engine parameters such as compressor discharge pressure, thereby avoiding the thermal and mechanical issues associated with pneumatic actuation in high-temperature environments.
2Ease of operation
If high-pressure, high-temperature air from the compressor is used to actuate the valve, then the valve can be controlled, but the temperature of the lubricant flowing through the valve increases, decreasing lubricant density and viscosity
Solution Approach 1:
The patent replaces the high-temperature pneumatic actuation system with an electronic control system that does not introduce additional heat to the lubricant. The electronic actuator and control valve system regulates lubricant flow without using compressed air, thereby preventing temperature increase and maintaining lubricant density and viscosity.
Solution Approach 2:
The invention introduces an electronic control system as an intermediary between the engine operating conditions and the valve actuation. This intermediary system processes engine parameters and generates appropriate control signals without directly contacting or heating the lubricant, thus maintaining lubricant temperature within acceptable ranges.
3Reliability
If the oil supply system is sized to ensure sufficient oil supply at maximum gear torque level, then proper operation is maintained at maximum torque, but at gear torque levels below maximum, excess lubricant is supplied causing the gearbox to churn the lubricant
Solution Approach 1:
The patent implements dynamic lubricant flow control that adapts to varying engine load conditions. The control valve adjusts the lubricant flow rate in real-time based on measured compressor discharge pressure or other engine parameters, ensuring optimal lubricant supply matches the actual torque demands of the gearbox. This dynamic adjustment prevents excess lubricant supply at partial load conditions while maintaining adequate supply at maximum load.
Solution Approach 2:
The invention employs a feedback control system where a controller continuously monitors engine operating parameters such as compressor discharge pressure and adjusts the control valve position accordingly. This closed-loop control ensures that lubricant flow is precisely matched to the actual torque requirements, eliminating the need for oversized supply systems and preventing energy-wasting lubricant churning at partial load conditions.
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 solution ensures precise control of lubricant flow, reducing energy wastage and maintaining optimal lubrication levels, thereby enhancing the efficiency and service life of the gas turbine engine components.
Implementation Method 1
The electromechanical valve actuator is coupled to the valve element and is responsive to actuator commands to move the valve element to the plurality of valve element positions
Implementation Method 2
The control valve includes a lubricant inlet, a lubricant outlet, and a valve element. The lubricant inlet is in fluid communication with a pressurized lubricant source, the lubricant outlet is in fluid communication with the gas turbine engine component
Implementation Method 3
The control valve further includes a flow chamber disposed between the lubricant inlet and the lubricant outlet, and the flow chamber has a plurality of first flow orifices and a plurality of second flow orifices
Implementation Method 4
The engine controller is coupled to receive a pressure sensor signal indicative of a compressor pressure sensed in the gas turbine engine
Data Source
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AI summary
A system for controlling lubricant flow to a component in a gas turbine engine includes a control valve (172), an electromechanical actuator (174), and an engine controller (112). The control valve includes a lubricant inlet that is in fluid communication with a pressurized lubricant source, a lubricant outlet is in fluid communication with the gas turbine engine component, and a valve element that is movable to a plurality of valve positions. The electromechanical valve actuator is coupled to the valve element and is responsive to actuator commands to position the valve element. The engine controller is coupled to receive a pressure sensor signal indicative of a compressor pressure in the gas turbine engine and, in response, determines a commanded valve element position and supplies the actuator commands to the electromechanical valve actuator that cause the electromechanical valve actuator to move the valve element to the commanded valve element position.