Patch Antenna Array Sensor for Gas Turbine Blade Tip Clearance
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Solution Overview
Problem
Existing blade tip sensors in gas turbine engines face limitations in accurately detecting blade tip clearance and wear, leading to inefficiencies and maintenance challenges due to their design and materials used.
Innovation Solution
A patch antenna array sensor embedded in a ceramic matrix composite body is integrated into the engine shroud, utilizing a phased array antenna system with an abradable layer to detect blade tip clearance and wear by emitting and receiving signals to determine the distance and shape of the blade tips, enabling precise monitoring and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional blade tip sensors are used, then the sensor structure is simple, but the measurement precision of blade tip clearance is insufficient
Solution Approach 1:
The sensor is divided into multiple patch antenna elements arranged in an array configuration. Each element independently measures electromagnetic signals, and their combined data provides precise blade tip clearance measurement through signal processing and correlation analysis.
Solution Approach 2:
The sensor integrates patch antenna elements with ceramic matrix composite (CMC) material, combining the electromagnetic sensing capability of the antenna with the high-temperature resistance and structural integrity of CMC, enabling accurate measurement in harsh engine environments.
2Measurement precision
If sensors are placed close to blade tips for accurate measurement, then measurement precision improves, but the sensor becomes more vulnerable to damage from high temperature and mechanical stress
Solution Approach 1:
The use of ceramic matrix composite (CMC) material provides exceptional high-temperature resistance and mechanical strength, allowing the sensor to operate reliably in the harsh thermal and mechanical environment near blade tips while maintaining measurement precision.
Solution Approach 2:
The sensor design anticipates harsh operating conditions by incorporating CMC material that inherently resists thermal degradation and mechanical stress before exposure, ensuring durability and continuous reliable operation in high-temperature engine environments.
3Temperature
If conventional sensor materials are used, then manufacturing is easier, but the sensor cannot withstand high-temperature engine conditions
Solution Approach 1:
The integration of patch antenna elements with CMC material creates a composite structure that inherits the high-temperature resistance of ceramics while maintaining the electromagnetic functionality of the antenna, enabling operation in engine environments exceeding 1000°C.
Solution Approach 2:
The sensor combines two distinct functional components—the electromagnetic patch antenna for measurement and the CMC structural material for thermal resistance—into a single integrated sensor assembly that simultaneously achieves both sensing capability and high-temperature durability.
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 solution provides accurate and reliable detection of blade tip clearance and wear, improving fuel efficiency, reducing maintenance needs, and enabling early detection of potential issues, such as blade creep and over-speed conditions, while being cost-effective and compatible with high-temperature engine components.
Implementation Method 1
a patch antenna array sensor including a patch antenna array embedded in a ceramic matrix composite body, wherein the patch antenna array sensor is configured to detect blade tip clearance
Data Source
AI summary
A patch antenna array sensor is provided. The patch antenna array sensor includes a ceramic matrix composite body in which a patch antenna array is embedded, wherein the patch antenna array sensor is configured to detect blade tip clearance or some other aspect of one or more blades in a gas turbine engine.