Turbine Vane Cooling Air Flow Measurement via Integrated Pressure Sensor
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Solution Overview
Problem
Existing gas turbine engine vane cooling systems lack efficient methods to monitor and manage cooling air flow, leading to potential blockages and inefficiencies in airfoil cooling, which can result in reduced engine performance and increased maintenance costs.
Innovation Solution
The integration of a turbine vane flow port system that includes a pressure sensor to measure cooling air pressure, allowing for real-time monitoring and diagnostic capabilities, and a bi-cast construction of airfoils and end walls to secure the end walls to the airfoil without a metallurgical bond, facilitating the placement of a pressure tap for flow measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional gas turbine engine vane cooling systems are used without integrated flow measurement, then the engine structure remains simpler and manufacturing is easier, but cooling air flow cannot be monitored leading to potential blockages and inefficiencies
Solution Approach 1:
The patent combines the cooling air flow measurement function with the existing vane structure by integrating a flow port directly into the vane body. This merging approach allows cooling air flow monitoring to be incorporated without adding separate external measurement devices, thus achieving precise measurement while minimizing additional structural complexity
Solution Approach 2:
The vane structure is designed to serve multiple functions: it provides structural support for the airfoil, delivers cooling air through internal passages, and incorporates a flow port for flow measurement. This multi-functionality allows the same component to handle both structural and measurement tasks, reducing overall system complexity while enabling precise flow monitoring
2Temperature
If cooling air is supplied to airfoils to withstand high temperatures, then the airfoils can operate at higher temperatures, but the cooling air consumption increases and requires monitoring
Solution Approach 1:
The patent implements a feedback mechanism by providing flow measurement data from the integrated flow port to monitoring systems. This feedback enables real-time tracking of cooling air consumption, allowing operators to optimize cooling air supply, detect blockages, and ensure efficient operation while maintaining the airfoil's temperature tolerance capabilities
3Strength
If end walls are securely attached to airfoils using traditional metallurgical bonding, then the structural strength is improved, but the ability to integrate flow measurement devices is reduced
Solution Approach 1:
The patent segments the vane structure into distinct components (airfoil, end walls, and flow port features) that can be manufactured separately and then assembled. This segmentation allows the flow port to be integrated into the end wall or airfoil structure through mechanical means rather than requiring metallurgical bonding, facilitating easier manufacturing and integration of measurement devices while maintaining structural integrity
Data Source
AI summary
Vanes for use in gas turbine engines and methods of measuring cooling air flow through vanes are disclosed herein. Each vane includes an airfoil and an end wall. The airfoil is shaped to interact with hot gasses moving along a primary gas path during operation of the gas turbine engine. The end wall is coupled to the airfoil and shaped to define a boundary of the primary gas path near a radial end of the airfoil. The end wall includes a platform that is exposed to the primary gas path and a projection that extends away from the platform and is located outside the primary gas path.