Modulated Turbine Cooling System for Engine Efficiency

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Solution Overview

Problem

Gas turbine engines operate with excess cooling flow due to fixed cooling systems, leading to decreased efficiency and increased fuel consumption, as they are typically designed for maximum turbine inlet temperature conditions, which are not always met in real operations.

Innovation Solution

A modulated turbine cooling (MTC) control system that adjusts cooling flow based on engine component health and operating conditions, using a processor to determine and modify cooling flow requirements, thereby optimizing cooling air distribution through MTC valves.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If fixed cooling flow is provided to turbine components, then cooling requirement at maximum turbine inlet temperature is met, but efficiency decreases and fuel consumption increases during normal operation

Engineering Contradiction:

Improveturbine component temperatureVSAvoidfuel consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The cooling flow rate is made dynamic rather than fixed. The system continuously adjusts the cooling flow rate based on real-time turbine inlet temperature measurements, ensuring adequate cooling only when actually needed. This resolves the contradiction by making the cooling system adaptive to operating conditions, reducing unnecessary cooling during normal operation while maintaining protection at maximum temperature conditions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the operating parameter of cooling flow rate based on turbine inlet temperature conditions. By monitoring turbine inlet temperature and adjusting cooling flow accordingly, the system optimizes the balance between component temperature control and fuel consumption, providing maximum cooling only when turbine inlet temperature reaches critical levels.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If excess cooling flow is provided to turbine components, then cooling requirement is always met, but engine efficiency decreases

Engineering Contradiction:

Improvecomponent cooling reliabilityVSAvoidengine efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system implements feedback control by continuously measuring turbine inlet temperature and using this information to adjust cooling flow rate. This feedback mechanism ensures reliable cooling protection is maintained when needed while eliminating excess cooling during normal operation, thus resolving the contradiction between cooling reliability and engine efficiency.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The cooling system transitions from a static, always-on approach to a dynamic, condition-based approach. By making cooling flow rate adjustable based on actual operating conditions, the system maintains reliability when required while optimizing efficiency during normal operation.

Inventive Principle:

Principle #15Dynamics

3Device complexity

If fixed cooling flow is used, then system complexity is low, but adaptability to different operating conditions is poor

Engineering Contradiction:

Improvecooling control system complexityVSAvoidcooling flow adaptability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The system changes the cooling flow rate parameter dynamically based on turbine inlet temperature conditions. This allows the simple cooling system structure to adapt to different operating conditions, resolving the contradiction between low complexity and high adaptability.

Inventive Principle:

Principle #35Parameter changes

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 MTC control system reduces specific fuel consumption and extends engine component life by providing the necessary cooling flow only when required, improving efficiency and time-on-wing.

Implementation Method 1

channel the determined required flow to the engine component during each respective operating condition

Methodology Applied

Scientific EffectFluid flow control:

Implementation Method 2

provide cooling air to turbine rotor components, such as turbine blades, to limit the temperatures experienced by such components

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS10794286B2Method and system for modulated turbine cooling as a function of engine health

Publication Date: 2020.10.06 GENERAL ELECTRIC CO

AI summary

A method of modulating cooling flow to an engine component based on a health of the component is provided. The method includes determining a cooling flow requirement of the engine component for each of a plurality of operating conditions and channeling the determined required flow to the engine component during each respective operating condition of the plurality of operating conditions. The method also includes assessing a health of the engine component. The method further includes modifying the determined cooling flow requirement based on the assessed health of the engine component, and supplying the modified cooling flow requirement to the engine component during each subsequent respective operating condition of the plurality of operating conditions.