Wireless Telemetry for Gas Turbine Blades
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Solution Overview
Problem
In gas turbine engines, existing instrumentation methods using wire leads and thermocouples result in extensive networks of wires for monitoring temperature, which can breach the pressure boundary and are not suitable for high-temperature environments, leading to potential deterioration and inefficiency.
Innovation Solution
The development of wireless telemetry systems where sensors and connectors are directly deposited onto components, using materials like silicon-on-insulator technology and high-temperature resistant alloys, allowing for wireless data transmission of component conditions without the need for extensive wiring, and capable of operating in temperatures up to 300°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wire leads and thermocouples are used for temperature monitoring, then temperature measurement capability is achieved, but device complexity and wire network extent increase significantly
Solution Approach 1:
The patent extracts the temperature sensing function from the mechanical wire/thermocouple system and integrates it directly into the semiconductor device structure. The sensor is formed within the semiconductor substrate itself, eliminating the need for separate wire leads and external thermocouples, thus reducing device complexity while maintaining measurement capability.
Solution Approach 2:
The patent merges the temperature sensing function with the semiconductor device structure by forming the sensor within the substrate. This integration combines multiple functions (device operation and temperature monitoring) into a single unified structure, eliminating the separate wire network and reducing overall system complexity.
2Measurement precision
If wire leads are routed through the component, then temperature monitoring is enabled, but pressure boundary integrity is compromised
Solution Approach 1:
The patent removes the wire leads that breach the pressure boundary and replaces them with an integrated sensor formed within the semiconductor substrate. This extraction eliminates the source of pressure boundary compromise while preserving temperature monitoring capability through the integrated sensing structure.
Solution Approach 2:
The patent introduces an integrated sensor as an intermediary element that enables temperature monitoring without requiring external wire connections through the pressure boundary. The sensor acts as a mediator between the internal environment and monitoring systems, maintaining pressure boundary integrity while enabling measurement.
3Measurement precision
If extensive wire networks are used for sensor connections, then monitoring coverage is improved, but susceptibility to deterioration in high-temperature environments increases
Solution Approach 1:
The patent merges the sensing function with the semiconductor device structure, creating an integrated sensor that is inherently protected by the device housing and packaging. This integration eliminates exposed wire networks that are susceptible to high-temperature deterioration while maintaining comprehensive monitoring coverage through the embedded sensor.
Solution Approach 2:
The patent utilizes the semiconductor substrate and associated packaging materials as a composite structure that provides both sensing functionality and environmental protection. The multi-layer composite structure protects the sensing elements from high-temperature deterioration while enabling monitoring coverage.
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 efficient monitoring of gas turbine engine components by minimizing wire networks, reducing the risk of pressure boundary breaches, and allowing for reliable data transmission in harsh high-temperature environments, thus enhancing operational efficiency and durability.
Implementation Method 1
a wireless telemetry device (76) mounted on a rotating component of the combustion turbine engine and configured to wirelessly transmit data
Data Source
AI summary
An instrumented component (18, 19) for use in various operating environments such as within a combustion turbine engine (10). The component (18, 19) may have a substrate, a sensor (50, 94, 134) connected with the substrate for sensing a condition of the component (18, 19) during operation of the combustion turbine (10) and a connector (52, 92, 140) attached to the substrate and in communication with the sensor (50, 94, 134) for routing a data signal from the sensor (50, 94, 134) to a termination location (53). The component (18, 19) may include a wireless telemetry device (54, 76, 96) in communication with the connector (52, 92, 140) for wirelessly transmitting the data signal. Recesses (114, 116) may be formed with a root portion (112, 132) of components (18, 19) within which wireless telemetry device (54, 76, 96) may be affixed.