Modulating Cooling Air Fleet Management for Gas Turbines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gas turbine engine cooling systems provide a relatively constant cooling potential across all aircraft engines, failing to adapt to varying operational conditions and environmental challenges, which can lead to inefficiencies and potential damage to components.
Innovation Solution
A modulating cooling system using an intercooled cooling air system that adjusts cooling potential based on specific engine conditions and operational demands, employing a cooling compressor that compresses air to higher pressures during high-power operations and reduces airflow during lower power conditions, allowing for tailored cooling according to flight routes, component health, and environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a constant cooling system is provided for all engines in the fleet, then the cooling coverage is comprehensive, but the cooling efficiency is reduced due to inability to adapt to varying operational conditions
Solution Approach 1:
The cooling system is made dynamic by enabling modulation of cooling airflow based on operational conditions. The system transitions from a static constant cooling mode to a dynamic adaptive mode where cooling airflow is adjusted according to real-time engine parameters, environmental conditions, and component health status, thereby optimizing cooling efficiency while maintaining comprehensive coverage.
Solution Approach 2:
The system changes operational parameters of the cooling airflow based on varying conditions. By monitoring engine operating parameters, environmental factors, and component health, the system adjusts cooling airflow parameters (volume, pressure, distribution) to match actual cooling needs, resolving the contradiction between comprehensive coverage and efficient energy use.
2Reliability
If cooling airflow is increased to meet high-power operational demands, then component protection is improved, but energy consumption increases
Solution Approach 1:
The cooling system implements periodic modulation of airflow based on operational cycles. During high-power operations, cooling airflow is increased to provide necessary component protection. During lower power conditions, cooling airflow is reduced. This periodic adjustment aligns energy consumption with actual cooling demands while maintaining component protection when needed.
Solution Approach 2:
The system dynamically changes cooling airflow parameters based on operational demands. By monitoring power output and thermal loads, the system adjusts airflow volume and pressure to provide adequate component protection during high-power operations while reducing energy consumption during lower demand periods.
3Adaptability or versatility
If a complex monitoring and control system is implemented to modulate cooling, then cooling adaptability is improved, but device complexity increases
Solution Approach 1:
The monitoring and control system is designed with multi-functionality to manage various aspects of cooling modulation. A single integrated control system performs multiple functions including monitoring operational parameters, assessing component health, evaluating environmental conditions, and adjusting cooling airflow distribution. This universal approach provides high cooling adaptability while minimizing the addition of separate dedicated systems.
Solution Approach 2:
The cooling system incorporates self-service capabilities where the control system automatically adjusts cooling parameters based on sensor inputs and pre-programmed logic. The system monitors its own operational state and makes autonomous decisions about cooling airflow modulation, reducing the need for complex external control mechanisms and manual intervention.
4Duration of action of stationary object
If cooling is provided continuously at high potential, then component life is extended, but energy efficiency deteriorates
Solution Approach 1:
The cooling system transitions from continuous static high-potential cooling to dynamic adaptive cooling. By continuously monitoring component health status, operational conditions, and environmental factors, the system adjusts cooling potential in real-time, providing high cooling when component life extension is critical while reducing cooling when conditions permit, thereby extending component life without continuous high energy consumption.
Solution Approach 2:
The system changes cooling parameters (airflow volume, pressure, temperature) based on actual component needs and operational conditions. By adjusting these parameters dynamically, the system extends component life through adequate cooling when necessary while improving energy efficiency by reducing cooling intensity when operational conditions and component status allow.
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
This approach enhances cooling efficiency, reduces energy consumption, and extends the life of engine components by matching cooling potential with operational demands, thereby optimizing performance and reducing maintenance costs.
Implementation Method 1
employing a cooling compressor that compresses air to higher pressures during high-power operations
Implementation Method 2
intercooled cooling air system that adjusts cooling potential based on specific engine conditions
Data Source
Figure 1
Figure 2A~3
Figure 4
AI summary
A method of modulating cooling of gas turbine engine components includes the steps of identifying an input indicative of a usage rate for at least a first gas turbine engine component of a plurality of gas turbine engine components. A cooling system (100;550) is operated for at least the first gas turbine engine component. The cooling system (100;550) is moved between a higher cooling potential mode and a lower cooling potential mode based on the identified rate. A gas turbine engine (20) is also disclosed.