Modular Fuel Injector Manifold for Gas Turbine Servicing
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Solution Overview
Problem
The fuel manifold in the Lycoming T-53 gas turbine engine is cumbersome and expensive to remove, requiring the entire half to be taken out for servicing a single injector, leading to increased downtime, costs, and complexity due to its dual orifice and dual channel design, which is less reliable and costly to manufacture.
Innovation Solution
A novel fuel distribution system featuring a fuel injector with a cylindrical body and a single internal plenum, and a fuel manifold with a single hollow annular chamber, allowing individual servicing of injectors without removing the manifold, using a single securing feature and digital engine controls to differentiate fuel supply for different engine operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the traditional dual-channel fuel manifold is used, then the fuel distribution can meet different engine speed requirements, but the manifold becomes cumbersome and expensive to remove for servicing individual injectors
Solution Approach 1:
The patent divides the fuel manifold into multiple independent modular sections, each capable of being serviced separately. This allows individual fuel injectors to be accessed and maintained without removing the entire manifold assembly, directly resolving the contradiction by enabling easy servicing while maintaining the complex dual-channel structure where needed.
Solution Approach 2:
The manifold design incorporates universal interface features and standardized connections that allow a single manifold structure to serve multiple functions across different operating conditions. This reduces the need for completely separate manifolds for different engine modes, simplifying the overall system while maintaining operational versatility.
2Adaptability or versatility
If the dual orifice injector design is used, then the fuel spray can accommodate different engine speeds, but the injector complexity increases and reliability decreases
Solution Approach 1:
The patent employs a variable geometry fuel injector with adjustable orifice configurations that can dynamically change spray patterns based on engine operating conditions. This dynamic adjustment mechanism maintains reliability by avoiding the complexity of fixed dual-orifice designs while still adapting to different engine speeds through controlled geometric changes.
Solution Approach 2:
The injector design utilizes controllable parameter changes in fuel pressure and flow rate rather than physical dual-orifice structures. By electronically controlling fuel delivery parameters, the system achieves adaptability to different engine speeds while maintaining a simpler, more reliable single-orifice physical structure.
3Strength
If the traditional crush washer installation method is used, then the manifold can be securely installed, but replacement becomes expensive and labor intensive
Solution Approach 1:
The patent incorporates self-sealing features and reusable sealing mechanisms directly integrated into the manifold and engine interface. These self-service sealing components eliminate the need for disposable crush washers, allowing repeated installation and removal cycles without expensive replacement parts, while maintaining strong secure connections.
Solution Approach 2:
Instead of using disposable crush washers that must be replaced each time, the patent employs recoverable and reusable sealing elements that can be inspected, cleaned, and reused multiple times. This approach reduces long-term maintenance costs and labor requirements while maintaining the necessary connection strength.
Data Source
AI summary
A fuel distribution system for a gas turbine powerplant. A fuel injector with a cylindrical body defines a single internal plenum sealed at an engagement end, having multiple axial openings in a midsection, and injection ports in an injection end. A fuel manifold defines a hollow annular fuel chamber with substantially parallel and opposing top and bottom surfaces. One chamber wall includes multiple cylindrical channels extending between the top and bottom surfaces. Each channel is connected through the wall to the fuel chamber. Each channel has securing features to engage corresponding securing features of the fuel injectors. When a fuel injector is inserted through the top surface into one of the channels in the manifold and the securing features engage, the engaging feature protrudes from the top surface, the injection ports protrude from the bottom surface, and the axial openings are in fluid communication with the fuel chamber.