Gas Turbine Heat Exchanger Bracket with Wear Material

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Solution Overview

Problem

Existing mounting systems for surface heat exchangers in gas turbine engines are complex, heavy, and prone to warping, leading to high manufacturing costs and potential high cycle fatigue, while also limiting thermal growth and ease of installation.

Innovation Solution

A surface heat exchanger system utilizing forward and aft brackets with low-friction wear materials and isolator sheets that provide spring force, allowing for thermal expansion and damping of high cycle fatigue, while being easily manufactured and installed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional mounting systems are used for surface coolers, then the heat exchanger can be securely mounted, but the mounting system becomes heavy and complex to manufacture

Engineering Contradiction:

Improvemounting securityVSAvoidmounting system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mounting system is divided into separate brackets that attach to the heat exchanger body, with distinct grooves for radial and axial positioning. This segmentation allows each component to be manufactured independently and assembled together, reducing overall system complexity while maintaining secure mounting.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A low-friction wear material is introduced as an intermediary layer between the cooler ribs and bracket grooves. This intermediate material reduces direct metal-to-metal contact, allowing for thermal expansion while maintaining secure mounting, thereby simplifying the overall mounting system design.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If traditional mounting systems with multiple welds are used, then the heat exchanger can be securely attached, but the metal of the surface cooler may warp

Engineering Contradiction:

Improveattachment securityVSAvoidcooler geometry

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The mounting system replaces traditional welding mechanisms with a mechanical bracket-based attachment system. The brackets use grooves and wear materials to secure the heat exchanger through friction and geometric constraint rather than thermal welding, eliminating the risk of warping from weld heat while maintaining secure attachment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If rigid mounting systems are used, then the heat exchanger is firmly positioned, but thermal growth in the circumferential direction is restricted

Engineering Contradiction:

Improveposition stabilityVSAvoidthermal expansion capability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The mounting system transitions from a completely rigid structure to a dynamic system that can adapt to thermal conditions. The low-friction wear materials and isolator sheets allow the heat exchanger to dynamically adjust its position during thermal expansion while the brackets maintain overall positional stability through gravitational and frictional forces.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The mounting system is specifically designed to accommodate thermal expansion in the circumferential direction. The grooves and wear materials allow the heat exchanger to expand outward radially while the brackets prevent excessive movement, creating a system that embraces thermal growth rather than resisting it.

Inventive Principle:

Principle #37Thermal expansion

4Reliability

If conventional mounting brackets are used, then the heat exchanger can be supported, but high cycle fatigue may occur in the cooler structure

Engineering Contradiction:

Improvesupport capabilityVSAvoidservice life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The mounting system incorporates cushioning elements in the form of low-friction wear materials and isolator sheets that are installed beforehand to protect the cooler structure. These elements absorb and distribute mechanical stresses before they can concentrate on the cooler ribs, preventing high cycle fatigue and extending service life.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 effectively stabilizes the heat exchanger while allowing for circumferential movement, reducing the risk of fatigue and manufacturing complexity, and enabling easier installation and maintenance.

Implementation Method 1

The low-friction wear material allows circumferential movement of the forward and aft cooler ribs therethrough

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

an isolator sheet which provides some spring force on the heat exchanger

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

The isolator sheet provides damping for high cycle fatigue

Methodology Applied

Scientific EffectDamping: Damping

Data Source

PatentUS9677474B2Surface cooler support mechanism

Publication Date: 2017.06.13 UNISON INDUSTRIES LLC

AI summary

A surface heat exchanger is provided which utilizes forward and aft brackets to retain the heat exchanger in position. The surface heat exchanger includes a plurality of core cooling channels as well as fins which are disposed for air flow through the gas turbine engine. The brackets include a low-friction wear material as well as an isolator sheet which provides some spring force on the heat exchanger.