Tangential On-Board Injection Vanes Fillet Radius Optimization
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Solution Overview
Problem
Existing tangential on-board injection (TOBI) systems for gas turbine engines lack improved design features that enhance cooling capacity and overall engine performance, particularly in terms of airfoil geometry and manufacturing complexity.
Innovation Solution
A TOBI system design featuring radially extending airfoils with specific fillet radii of curvature and geometric configurations between endwalls, optimized for improved cooling effectiveness and manufacturing ease, including a method of casting to produce the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If airfoils with small fillet radii are used in TOBI systems, then manufacturing precision and quality control are improved, but cooling effectiveness and flow characteristics deteriorate
Solution Approach 1:
The patent applies parameter changes by transitioning from small fillet radii to large fillet radii (e.g., 0.07 inches or 1.8 mm) on airfoil leading edges. This parameter modification simultaneously improves cooling effectiveness by enhancing tangential flow characteristics while remaining compatible with casting manufacturing processes, thus resolving the contradiction between manufacturing precision and cooling effectiveness
2Temperature
If complex airfoil geometries are designed to improve cooling capacity, then cooling effectiveness is enhanced, but manufacturing complexity and production difficulty increase
Solution Approach 1:
The patent applies local quality by implementing large fillet radii specifically at critical locations (airfoil leading edges) where flow characteristics are most important, while maintaining simpler geometries in other regions. This localized geometric modification enhances cooling effectiveness through improved flow attachment without significantly increasing overall manufacturing complexity
Solution Approach 2:
The patent utilizes spheroidality by incorporating large rounded fillet radii at airfoil leading edges instead of sharp corners. This curvature modification improves flow characteristics and cooling effectiveness while being well-suited for casting processes, thereby enhancing cooling capacity without proportionally increasing manufacturing complexity
3Ease of manufacture
If traditional TOBI system designs are used, then manufacturing processes are simpler, but cooling effectiveness and engine performance are insufficient
Solution Approach 1:
The patent modifies traditional TOBI system designs by changing geometric parameters, specifically implementing large fillet radii (e.g., 0.07 inches) on airfoils. This parameter change improves cooling effectiveness and engine performance while remaining compatible with existing casting manufacturing processes, thus maintaining manufacturing simplicity
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 design enhances cooling effectiveness by maintaining tangential fluid flow and reduces size and weight, while simplifying the manufacturing process to meet quality control standards for intricate geometries.
Implementation Method 1
The radius of curvature of the first and second fillet portions proximate to the leading edge of the airfoil is larger than the radius of curvature of the first and second fillet portions proximate to the trailing edge
Data Source
AI summary
A tangential on-board injection (TOBI) system for gas turbine engines includes a first endwall and a second endwall radially spaced apart from the first endwall. A plurality of airfoils extend radially from the first endwall to the second endwall. Each airfoil has a leading edge and a trailing edge. Each airfoil includes a first fillet portion transitioning between the airfoil and the first endwall and a second fillet portion transitioning between the airfoil and the second endwall. The radius of curvature of the first and second fillet portions proximate to the leading edge of the airfoil is larger than the radius of curvature of the first and second fillet portions proximate to the trailing edge.