Pneumatic-Cooled Controller Assembly for Hot-Running Actuators
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Solution Overview
Problem
Controllers used in gas turbine engines face challenges in withstanding high temperature and pressure environments, leading to thermal limitations that affect their operational reliability and efficiency.
Innovation Solution
A controller assembly comprising an electromechanical actuator and a single-stage pneumatic flow switch that provides thermal protection by supplying cooling fluid, allowing the actuator to operate beyond its thermal design point by creating a cooling jacket around thermally sensitive components, and only providing cooling when necessary to minimize parasitic cooling flows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electromechanical actuator is placed in a hot environment to control bleed air, then the controller can function in the required operational environment, but the actuator exceeds its thermal capability and reliability deteriorates
Solution Approach 1:
The controller assembly is segmented into distinct thermal zones: a hot environment zone for the valve body exposed to bleed air, and a cooled zone for the electromechanical actuator surrounded by a cooling jacket. This spatial segmentation allows each component to operate within its optimal thermal range, resolving the contradiction between environmental adaptability and reliability.
Solution Approach 2:
A cooling fluid acts as an intermediary substance, introduced through a cooling flow passage and distributed via a cooling jacket around the actuator. This intermediary creates a thermal barrier between the hot bleed air environment and the temperature-sensitive electromechanical actuator, enabling the actuator to maintain reliability while the controller operates in the required hot environment.
2Reliability
If cooling fluid is continuously supplied to the actuator, then thermal protection is maintained, but parasitic cooling flows increase energy consumption
Solution Approach 1:
The cooling system transitions from a static continuous flow design to a dynamic on-demand system. A pneumatic flow switch dynamically controls the cooling fluid supply based on real-time operational conditions, opening the cooling flow passage when cooling is needed and closing it when not required. This dynamic control maintains actuator thermal protection while eliminating unnecessary parasitic cooling flows and reducing energy consumption.
3Temperature
If a cooling system is added to protect the actuator, then thermal capability is improved, but device complexity increases
Solution Approach 1:
The cooling fluid flow passage serves multiple functions: it provides thermal protection to the actuator, acts as a sealing mechanism, and integrates with the existing valve body structure. The pneumatic flow switch that controls cooling also manages other fluid flows in the system. This multi-functionality approach improves thermal capability while minimizing the increase in device complexity by leveraging existing system components.
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
Enables the actuator to function reliably in hotter environments than its thermal capability, reduces unnecessary cooling, and eliminates the need for costly controller banks by integrating the control assembly within the valve, thereby reducing complexity, weight, and cost.
Implementation Method 1
The switch is configured to thermally protect the electromechanical actuator by a supply of cooling fluid
Implementation Method 2
a single-stage pneumatic flow switch
Data Source
Figure 1~2
Figure 3A
Figure 3B
AI summary
A controller assembly (100) comprises an electromechanical actuator (102) and a single-stage pneumatic flow switch (104) configured to thermally protect the electromechanical actuator (102) by a supply of cooling fluid. The single-stage pneumatic flow switch (104) is movable between a first mode in which the switch is configured to open a cooling fluid flow passage (106) and a second mode in which the switch is configured to close the cooling fluid flow passage (106). The electromechanical actuator (102) is coupled to a valve (110) movable between an open and a closed configuration.