Impingement-Cooled Rotating Seal for Turbine Hot-Spot Heat Removal
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Solution Overview
Problem
Conventional cooling channels in rotating seals of gas turbine engines are limited by machining processes, restricting their ability to effectively dissipate heat generated at contact surfaces between rotating and stationary seals, leading to inefficient cooling and potential damage.
Innovation Solution
An impingement cooling approach is implemented using a ring-shaped rotating seal with a plenum and angled entrance and exit channels, where cooling fluid is forced to impinge against the hot side and move turbulently, forming a film to efficiently remove heat from the contact surfaces between rotating and stationary seals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling channels are used in rotating seals, then the structure is simple and easy to manufacture, but the cooling performance is insufficient due to limited channel locations and inability to reach hot spots
Solution Approach 1:
The cooling system is segmented into multiple functional components: entrance channels for fluid supply, a plenum chamber for distribution, and exit channels for fluid discharge. This segmentation allows each component to be optimized independently, with the plenum enabling cooling fluid to reach previously inaccessible hot spots through its strategic positioning and geometry
Solution Approach 2:
The cooling approach transitions from conventional linear channels to a three-dimensional plenum chamber structure. The plenum extends in multiple directions and can be positioned at various locations within the rotating seal body, enabling cooling fluid to access hot spots from multiple angles and dimensions rather than being constrained to single-path channel geometries
2Temperature
If cooling channels are positioned close to hot spots, then cooling effectiveness improves, but conventional machining processes cannot form channels in locations where oil can fully achieve the desired cooling effect
Solution Approach 1:
The patent replaces conventional mechanical machining processes with additive manufacturing technology. This substitution enables the creation of complex three-dimensional plenum chambers and cooling channel geometries that would be impossible or extremely difficult to produce using traditional machining methods, allowing cooling fluid to reach previously inaccessible hot spots
3Temperature
If compound angle cooling channels are used, then some cooling effect is achieved, but the overall cooling performance is limited by the inability to position channels optimally
Solution Approach 1:
The cooling system incorporates a dynamic plenum chamber that can be positioned and oriented to adapt to different hot spot locations within the rotating seal. The plenum's flexible positioning and three-dimensional structure allow the system to adapt to varying thermal conditions and operational requirements, providing versatile cooling coverage that conventional fixed-angle channels cannot achieve
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 heat removal capabilities at hot zones, preventing damage and improving engine performance by dispersing heat through the formation of cooling oil films, outperforming conventional cooling methods.
Implementation Method 1
the cooling fluid is forced by centrifugal force, during operations of the gas turbine engine in which the rotating seal rotates about the engine centerline, to enter and flow through the one or more entrance channels along radial outer surfaces to the plenum
Implementation Method 2
cooling fluid exiting the one or more entrance channels and entering the plenum is expelled in a jet-like flow from the outlets to impinge against the hot side
Implementation Method 3
cooling fluid exiting the one or more entrance channels and entering the plenum is expelled in a jet-like flow from the outlets to impinge against the hot side, and subsequently move in a turbulent manner between the hot side and the relatively cool side
Implementation Method 4
cooling fluid exiting the one or more entrance channels and entering the plenum is expelled in a jet-like flow from the outlets to impinge against the hot side, and subsequently move in a turbulent manner between the hot side and the relatively cool side
Implementation Method 5
forming a film of cooling fluid and exiting the plenum by the one or more exit channels
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A rotating seal (401) rotatable about a rotational axis (A) is provided. The rotating seal (401) includes a body (410) having a first surface (411) disposable to face the rotational axis (A) and a second surface (412) disposable to contact with a stationary element (230). The body (410) defines a cooling channel (420) including one or more entrance channels (430) respectively extending from the first surface (411), one or more exit channels (440) and a plenum (450). The plenum (450) extends circumferentially through the body (410) and has a hot side (451) adjacent to the second surface (412). The plenum (450) is fluidly interposed between the one or more entrance channels (430) and the one or more exit channels (440) whereby fluid exiting the one or more entrance channels (430) and entering the plenum (450) impinges against the hot side (451). A method of manufacturing the rotating seal (401) includes the additive manufacturing of the seal body (410).