Hybrid-Powered Electric Heating for Turbomachinery Tip Clearance Control
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Solution Overview
Problem
Traditional clearance control systems in gas turbine engines are large, heavy, expensive, and slow to respond, providing limited improvement in tip clearance, which affects engine efficiency.
Innovation Solution
A hybrid electric power system with a heating element and valve assembly for active bi-directional control of the outer structure, using a hybrid electric power source comprising batteries, capacitors, and generators to regulate power and cooling air flow for precise tip clearance management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional clearance control systems use valves and manifolds to direct fan air to engine case locations, then tip clearance is improved, but the system becomes large, heavy, expensive, and slow to respond
Solution Approach 1:
The patent replaces the traditional mechanical valve and manifold system with an electrical heating element system. Instead of using complex mechanical components to direct cooling air, the invention uses electrical heating elements to thermally expand the outer structure, thereby controlling tip clearance through thermal effects rather than mechanical air flow manipulation.
Solution Approach 2:
The patent changes the physical parameter used for clearance control from mechanical air flow pressure to thermal expansion. By controlling the temperature of the outer structure through heating elements, the system achieves precise tip clearance control through thermal parameter changes rather than mechanical parameter adjustments.
2Manufacturing precision
If traditional clearance control systems use valves and manifolds, then tip clearance improvement is achieved, but response time increases
Solution Approach 1:
The electrical heating element system responds much faster than mechanical valve systems because electrical heating can be activated and adjusted almost instantaneously through electronic control, eliminating the mechanical response delays inherent in valve and manifold systems.
Solution Approach 2:
The heating element system can be rapidly cycled on and off or adjusted in intensity through electronic control, allowing for quick response to changing operational conditions and enabling precise, dynamic tip clearance control during engine operation.
3Reliability
If structures are made of different materials to withstand operational conditions, then reliability is improved, but differential thermal expansion causes blade rubbing or clearance increase
Solution Approach 1:
The patent deliberately utilizes thermal expansion of the outer structure as the control mechanism. By heating the outer structure through heating elements, the system causes controlled thermal expansion that increases tip clearance when needed, directly addressing the differential thermal expansion problem between different structural materials.
Solution Approach 2:
The system changes the temperature parameter of the outer structure to actively control tip clearance. By adjusting the heating element power, the outer structure temperature is varied, which in turn varies the thermal expansion and thus the tip clearance, providing active control over the clearance that would otherwise be affected by differential thermal expansion.
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
Enables faster and more precise control of blade tip clearance, reducing response time and allowing tighter tolerances, thereby enhancing engine efficiency and performance.
Implementation Method 1
A hybrid electric power source (305) and controller (280) are provided for a clearance control system (200). A heating element (210) is configured to cause an outer structure (220) to vary in temperature in response to an electrical current being supplied thereto
Implementation Method 2
As these structures expand at different rates in response to temperature changes, the tip clearance may be reduced and the blade may rub on the BOAS
Implementation Method 3
The cooling air thermally shrinks the engine case at these locations to improve tip clearance
Data Source
Figure 1
Figure 2A~2C
Figure 2D
AI summary
A hybrid energy storage and control system for a clearance control system for a gas turbine engine (120) may comprise a hybrid electric power source (205; 305), a first converter, a second converter configured to receive electric power from the hybrid electric power source (205; 305) via the first converter and configured to send the electric power to a heating element (210; 310) for controlling a blade tip clearance (G) between a rotor blade and an outer structure of the gas turbine engine (120), and a controller (280) in electronic communication with the second converter. The hybrid electric power source (205; 305) may comprise a battery, a supercapacitor, and/or an ultracapacitor.