Additive Monolithic Inlet Frame for Gas Turbine Anti-Icing
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Solution Overview
Problem
Conventional gas turbine engine inlet frames with fluid distribution systems and manifolds require complex assembly, are costly, and prone to fluid leaks due to numerous joints, limiting their performance and reliability.
Innovation Solution
An additively manufactured inlet frame with integral fluid distribution systems and annular heating plenums, formed as a single monolithic component using 3D printing, which simplifies assembly, reduces parts, and enhances performance by integrating features like wash manifolds, discharge ports, and anti-icing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional inlet frames include multiple fluid manifolds, supply conduits, support structures, and spray nozzles assembled together, then the inlet frame can perform various fluid distribution functions, but the assembly complexity increases, manufacturing time and costs increase, and the likelihood of fluid leaks increases
Solution Approach 1:
The patent combines multiple separate components (fluid manifolds, supply conduits, support structures, spray nozzles) into a single integrated inlet frame component. This merging eliminates the need for complex assembly of multiple parts while maintaining all fluid distribution functions, directly resolving the contradiction between versatility and assembly complexity
Solution Approach 2:
The inlet frame is designed as a universal component that performs multiple functions simultaneously: structural support, fluid distribution, heating, and washing operations. By integrating these diverse functions into one component, the patent achieves multi-functionality without requiring separate assemblies for each function
2Ease of manufacture
If conventional inlet frames include multiple joints for connecting manifolds and conduits, then the inlet frame can be assembled from standardized parts, but the likelihood of fluid leaks increases due to the number of joints
Solution Approach 1:
By merging multiple separate parts into a single monolithic inlet frame component, the patent eliminates all joints and connections that would otherwise be required to assemble manifolds, conduits, and nozzles. This single-component approach removes the source of potential leaks while maintaining manufacturability through advanced manufacturing processes
3Ease of manufacture
If conventional inlet frames are assembled from multiple individual parts, then the inlet frame can be manufactured using traditional manufacturing methods, but the manufacturing time and costs are very high
Solution Approach 1:
The patent merges multiple manufacturing operations and assembly steps into a single manufacturing process. By creating the inlet frame as one integrated component, the patent eliminates time-consuming assembly operations while utilizing modern additive manufacturing technology to produce the complex geometry efficiently
Solution Approach 2:
The patent employs additive manufacturing technology, representing a fundamental change in the manufacturing parameter from traditional subtractive or formative methods. This parameter change enables the efficient production of complex integrated geometries that would be difficult or impossible to manufacture and assemble using conventional methods
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 additive manufacturing approach reduces assembly time and costs, minimizes leakage, and allows for complex geometries, improving the reliability and functionality of the inlet frame by integrating multiple features into a single component.
Implementation Method 1
Hot air tapped from the compressor passes through a supply conduit into an annular heating manifold defined in the forward annular body, where it prevents formation of ice
Implementation Method 2
a flow of heated fluid to the annular heating plenum
Data Source
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AI summary
An inlet frame (54) and a method (300) of heating an inlet screan of an inlet frame are provided. The inlet frame (54) includes a forward annular body (102) spaced apart from a rear annular body (104) to define an inlet passageway (106) in fluid communication with a compressor inlet (108). Inlet frame (54) defines one or more integral annular heating plenums (84), (186) in fluid communication with a hot air source (150) for heating regions of the inlet frame (54) that are prone to icing conditions.