Geared Turbofan Compressor High Exit Temperature Management

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Solution Overview

Problem

Gas turbine engines face challenges in achieving optimal thermal, transfer, and propulsive efficiencies, particularly at high exit temperatures in the compressor section of geared turbofan engines.

Innovation Solution

The design incorporates a geared architecture with a high bypass ratio and distinct blade and disk configurations in the compressor sections, including integrally formed blades without rim cavities or honeycomb seals, to manage high exit temperatures and reduce thermal discontinuities, enabling operation at temperatures between 1000° F and 1500° F.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the compressor section operates at high exit temperatures to improve propulsive efficiency, then thermal efficiency improves, but thermal mechanical fatigue and reliability deteriorate

Engineering Contradiction:

Improvethermal efficiencyVSAvoidthermal mechanical fatigue

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The compressor section is divided into multiple stages with distinct blade and disk configurations. Specifically, the compressor includes stages with traditional rim cavity designs and stages with integrally formed blades, creating segmented zones that manage thermal gradients and reduce thermal mechanical fatigue in the high-temperature operating regime.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different parts of the compressor section have different blade and disk configurations optimized for their specific thermal environments. The integrally formed blade configuration is applied in stages experiencing highest thermal loads, while traditional configurations are used in cooler stages, allowing each local region to operate optimally without compromising overall reliability.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If rim cavities and honeycomb seals are used in compressor blades, then manufacturing and sealing are easier, but thermal discontinuities and leakage increase

Engineering Contradiction:

Improveblade manufacturingVSAvoidleakage

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The invention extracts and eliminates the rim cavity structure from the compressor blade design in certain stages, replacing it with integrally formed blades. This removal of the rim cavity eliminates the source of thermal discontinuities and leakage paths, directly addressing the loss of substance problem while maintaining manufacturing feasibility through advanced casting or additive manufacturing processes.

Inventive Principle:

Principle #2Taking out (Extraction)

3Use of energy by moving object

If a geared architecture is used to drive the fan at reduced speed, then propulsive efficiency improves, but device complexity increases

Engineering Contradiction:

Improvepropulsive efficiencyVSAvoidgeared architecture

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The geared architecture is designed to serve multiple functions simultaneously: it provides speed reduction for the fan, accommodates high compressor exit temperatures, and integrates with the overall engine structure. The gear system is positioned and configured to handle both the propulsive efficiency requirement and the thermal management requirement, reducing the need for separate systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11560851B2Geared turbofan engine with high compressor exit temperature

Publication Date: 2023.01.24 RTX CORP

AI summary

A gas turbine engine comprises a fan includes a plurality of fan blades rotatable about an axis. A compressor section includes at least a first compressor section and a second compressor section, wherein components of the second compressor section are configured to operate at an average exit temperature that is between about 1000° F. and about 1500° F. A combustor is in fluid communication with the compressor section. A turbine section is in fluid communication with the combustor. A geared architecture is driven by the turbine section for rotating the fan about the axis.