Modular Airfoil Inserts for Turbomachine Cooling

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Solution Overview

Problem

Current rotor blade and guide vane designs for turbomachines face challenges in achieving adequate cooling and efficient cooling flow control, particularly in maintaining the integrity and performance of airfoil components under varying operating conditions and thermal stresses.

Innovation Solution

A modular design for rotor blades and guide vanes featuring separable airfoil portions, inner and outer platforms, with interchangeable inserts that can be secured through friction-locked bonding or force closure, allowing for improved cooling efficiency and adaptability to different operating regimes, including the use of various materials and thermal management strategies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional integral airfoil design is used, then manufacturing simplicity is maintained, but cooling efficiency and adaptability to varying operating conditions deteriorate

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidcooling efficiency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The airfoil is divided into multiple separable components including the airfoil portion, inner platform, outer platform, and interchangeable inserts. This segmentation allows each component to be optimized independently for cooling efficiency while maintaining manufacturing feasibility through modular assembly processes.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If fixed design airfoil is used, then manufacturing simplicity is maintained, but adaptability to different operating regimes deteriorates

Engineering Contradiction:

Improvedesign simplicityVSAvoidadaptability to operating regimes

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The airfoil incorporates interchangeable inserts that can be replaced or reconfigured to adapt to different operating regimes and thermal conditions. This dynamic reconfigurability allows the same basic airfoil structure to serve multiple operational requirements without requiring complete redesign.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The modular airfoil design with standardized interfaces and interchangeable inserts provides multi-functionality, allowing the same platform to accommodate various insert configurations for different operating conditions, materials, and cooling requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If adequate cooling is implemented, then thermal stress resistance is improved, but coolant consumption increases

Engineering Contradiction:

Improvethermal stress resistanceVSAvoidcoolant consumption

Core Design Contradiction:

TemperatureVSQuantity of substance

Solution Approach 1:

The cooling system is designed with localized cooling channels and inserts positioned at specific high-thermal-stress regions within the airfoil. This targeted approach provides adequate cooling where needed most while minimizing overall coolant consumption by avoiding unnecessary cooling in lower-stress areas.

Inventive Principle:

Principle #3Local quality

4Reliability

If modular design with interchangeable inserts is used, then adaptability and cooling efficiency are improved, but device complexity increases

Engineering Contradiction:

Improvecooling efficiencyVSAvoidstructural complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

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 modular design enhances cooling efficiency, extends component life, reduces coolant consumption, and allows for flexible material selection, improving aerodynamic performance and resistance to high temperature stresses, while enabling easier maintenance and repair of individual components.

Implementation Method 1

receive at least a portion of the cooling air entering the chamber of the insert and direct the cooling air through a plurality of insert apertures to cool the inner surface of the outer wall

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

direct the cooling air through a plurality of insert apertures to cool the inner surface of the outer wall

Methodology Applied

Scientific EffectImpingement cooling:

Implementation Method 3

interchangeable inserts that can be secured through friction-locked bonding

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentEP2921649B1Airfoil portion of a rotor blade or guide vane of a turbo-machine

Publication Date: 2021.04.28 ANSALDO ENERGIA IP UK LTD

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AI summary

An airfoil portion (100) having an outer wall that defines a cavity for receiving cooling air. At least one insert disposed within the cavity that is configured to initially receive at least a portion of the cooling air entering the chamber of the insert and direct the cooling air through a plurality of insert apertures to cool the inner surface of the outer wall of the airfoil portion. The insert further comprises a configuration that generally conforms to the contour of the outer wall of the chamber but in spaced relation thereto. A portion of the cooling air exits the airfoil portion through a plurality of film cooling apertures formed through the outer wall. A second insert (200) forms the trailing edge channel at the end of the main insert (106).