Gas Turbine Heat Exchanger Pylon Integration
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Solution Overview
Problem
Conventional Thermal Management Systems (TMS) heat exchanger placements in gas turbine engines often interrupt thrust airflow, leading to mixing losses that detract from engine efficiency due to long, serpentine ducts and placement within the core cowl area.
Innovation Solution
The TMS includes heat exchangers mounted within the bifurcation area in communication with the bypass flow of the gas turbine engine, reducing the need for long ducts and minimizing mixing losses by integrating directly into the bypass flow path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat exchangers are placed within core cowl area and axially deep within fan cowl, then thermal management function is achieved, but thrust airflow is partially interrupted and mixing losses increase
Solution Approach 1:
The heat exchanger is extracted from the conventional core cowl/fan cowl location and repositioned to the pylon structure. This removes the heat exchanger from the thrust airflow path, eliminating the interruption of airflow and the associated mixing losses while maintaining the thermal management function through alternative positioning in communication with bypass flow.
Solution Approach 2:
The heat exchanger placement transitions from an axial arrangement within the engine cowl to a lateral arrangement on the pylon structure. This dimensional change allows the heat exchanger to access bypass flow without interfering with the core thrust airflow path, thereby resolving the contradiction between thermal management and airflow efficiency.
2Temperature
If heat exchanger airflow is ducted inward toward engine centerline and then outward to merge with bypass stream, then heat exchange function is achieved, but ducts become long and serpentine reducing efficiency
Solution Approach 1:
The heat exchanger and its associated ducting are extracted from the engine core area and relocated to the pylon structure. This eliminates the need for long serpentine ducts that would be required to route airflow from a central position back to the bypass stream, as the heat exchanger is now positioned directly in communication with bypass flow.
Solution Approach 2:
Instead of ducting airflow inward toward the engine centerline and then outward (the conventional approach), the heat exchanger is positioned to directly access bypass flow moving outward from the engine. This inverted approach eliminates the unnecessary inward routing and reduces duct length significantly.
3Loss of energy
If heat exchanger is mounted within bifurcation area in communication with bypass flow, then mixing losses are minimized, but integration complexity increases
Solution Approach 1:
The pylon structure serves multiple functions: it provides structural support for the engine, acts as a mounting location for the heat exchanger, and provides access to bypass flow. By utilizing the pylon's existing structure and flow environment, the heat exchanger integration achieves thermal management functionality without requiring separate complex support structures or plumbing systems.
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 configuration reduces weight, minimizes support structure and plumbing, increases bypass aerodynamic efficiency, and decreases fan bypass area mixing losses, resulting in improved engine efficiency and reduced space requirements.
Implementation Method 1
at least one heat exchanger mounted within a bifurcation area in communication with a bypass flow of the gas turbine engine
Data Source
AI summary
A thermal management system includes at least one heat exchanger in communication with a bypass flow of a gas turbine engine. The placement of the heat exchanger(s) minimizes weight and aerodynamic losses and contributes to overall performance increase over traditional ducted heat exchanger placement schemes.