Mid-frame Torque Disc Cooling via Radial Bleed Air Channels
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Solution Overview
Problem
Conventional cooling systems in gas turbine engines face challenges in effectively cooling mid-frame torque discs, leading to high temperatures and potential material failure, despite using high-cost materials, which are costly and inefficient.
Innovation Solution
A cooling system that includes mid-frame cooling channels extending through mid-frame torque discs, utilizing compressor bleed air to create a de-swirling action and featuring thermal barrier coatings, allowing the use of conventional low-cost materials and reducing stress and blade tip clearances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high-cost materials with higher heat tolerance are used for mid-frame torque discs, then temperature resistance is improved, but manufacturing cost increases
Solution Approach 1:
The torque disc is divided into different radial zones with cooling channels positioned in the outer radial portion, creating segmented cooling zones that target specific high-temperature areas while leaving other areas with conventional material requirements
Solution Approach 2:
Cooling channels are positioned specifically in the radially outer portion of the torque disc where temperatures are highest, providing localized cooling protection that allows conventional materials to be used in less critical areas, reducing overall material cost while maintaining heat tolerance where needed
2Temperature
If conventional cooling systems are used for turbine components, then cooling coverage is improved, but stress and creep in mid-frame torque discs increase
Solution Approach 1:
The cooling system provides targeted cooling to the radially outer portion of the torque disc where temperatures are highest, reducing thermal stress and creep in critical areas without requiring expensive high-temperature materials throughout the entire component
Solution Approach 2:
Cooling channels are positioned in the radial dimension (outer radial portion) rather than uniformly distributed, creating a dimensional strategy that addresses temperature gradients and stress distribution more effectively
3Temperature
If cooling channels are positioned in radially outer portion of torque disc, then cooling efficiency is improved, but structural complexity increases
Solution Approach 1:
The cooling channel configuration is segmented into specific radial zones rather than requiring a complex three-dimensional network throughout the entire torque disc, simplifying manufacturing while maintaining cooling efficiency in critical areas
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 cooling system effectively reduces temperature gradients in mid-frame torque discs, enabling the use of cost-effective materials, improving efficiency by eliminating the need for alternative cooling sources, and extending the fracture life of torque discs.
Implementation Method 1
The inlet section is nonparallel and nonorthogonal to a longitudinal axis of the turbine engine to create de-swirling action for minimum pressure drop
Implementation Method 2
The cooling system effectively reduces temperature gradients in mid-frame torque discs
Implementation Method 3
one or more thermal barrier coatings on a radially outer surface of the mid-frame torque disc and aligned radially outward from the mid-frame cooling channel
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A cooling system (10) configured to cool aspects of the turbine engine (12) between a compressor (14) and a turbine assembly (16) is disclosed. In at least one embodiment, the cooling system (10) may include one or more mid-frame cooling channels (18) extending from an inlet (20) through one or more mid-frame torque discs (22) positioned downstream of the compressor (14) and upstream of the turbine assembly (16). The inlet (20) may be positioned to receive compressor bleed air. The mid-frame cooling channel (18) may be positioned in a radially outer portion of the mid-frame torque disc (22) to provide cooling to outer aspects of the mid-frame torque disc (22) such that conventional, low cost materials may be used to form the mid-frame torque disc (22) rather than high cost materials with capacity to withstand higher temperatures. The cooling fluid routed through the mid-frame cooling channel (18) in the mid-frame torque disc (22) may be exhausted into a cooling system (10) for the downstream turbine assembly (16).