U.S. patent application number 15/635420 was filed with the patent office on 2017-10-19 for aerodynamically active stiffening feature for gas turbine recuperator.
The applicant listed for this patent is PRATT & WHITNEY CANADA CORP.. Invention is credited to Daniel ALECU, Andreas ELEFTHERIOU, David Harold MENHEERE.
Application Number | 20170297079 15/635420 |
Document ID | / |
Family ID | 51521017 |
Filed Date | 2017-10-19 |
United States Patent
Application |
20170297079 |
Kind Code |
A1 |
ELEFTHERIOU; Andreas ; et
al. |
October 19, 2017 |
AERODYNAMICALLY ACTIVE STIFFENING FEATURE FOR GAS TURBINE
RECUPERATOR
Abstract
A method of manufacturing a recuperator disposed in the exhaust
duct of a gas turbine engine includes forming a first leading
recess adjacent a leading edge of a first thermally conductive
sheet and forming a second leading recess adjacent a leading edge
of a second thermally conductive sheet, the first and second
thermally conductive sheets forming components of a recuperator
plate. The first leading recess of the first thermally conductive
sheet is mated with the second leading recess of the second
thermally conductive sheet, and then the first and second leading
edges are joined thereby forming a recuperator plate. The first and
second leading recesses form a trough extending along a leading
edge of the recuperator plate in a direction substantially parallel
to a longitudinal axis of the recuperator plate.
Inventors: |
ELEFTHERIOU; Andreas;
(Woodbridge, CA) ; ALECU; Daniel; (Brampton,
CA) ; MENHEERE; David Harold; (Georgetown,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PRATT & WHITNEY CANADA CORP. |
Longueuil |
|
CA |
|
|
Family ID: |
51521017 |
Appl. No.: |
15/635420 |
Filed: |
June 28, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13804118 |
Mar 14, 2013 |
9724746 |
|
|
15635420 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F28D 7/1684 20130101;
F05D 2250/712 20130101; B21D 49/00 20130101; F02K 1/822 20130101;
Y02T 50/675 20130101; Y02T 50/60 20130101; Y02T 50/672 20130101;
F05D 2250/711 20130101; B21D 53/04 20130101; F01D 25/30 20130101;
F02C 7/08 20130101; F05D 2220/32 20130101; F28F 3/046 20130101;
F28F 13/02 20130101; F28D 2021/0026 20130101; F05D 2210/34
20130101; F28D 9/0031 20130101; F28F 13/06 20130101; Y10T 29/49357
20150115 |
International
Class: |
B21D 53/04 20060101
B21D053/04; F28F 13/02 20060101 F28F013/02; F28F 3/04 20060101
F28F003/04; F28D 7/16 20060101 F28D007/16; F28F 13/06 20060101
F28F013/06; F28D 9/00 20060101 F28D009/00 |
Claims
1. A method for manufacturing a recuperator for a gas turbine
engine, the method comprising: forming at least one recuperator
plate, the recuperator plate extending in a longitudinal direction
between an upstream and a downstream end spaced apart along a
longitudinal axis, the recuperator plate extending in a transverse
direction between a leading edge and a trailing edge thereof, each
of the leading edge and the trailing edge extending longitudinally
between the upstream and the downstream edges, the transverse
direction being substantially perpendicular to the longitudinal
direction defined by the longitudinal axis, forming the recuperator
plate including: providing first and second thermally conductive
sheets, respectively having a first sheet leading edge and a first
sheet trailing edge, and a second sheet leading edge and a second
sheet trailing edge; forming a first leading recess adjacent the
first sheet leading edge of the first thermally conductive sheet,
and forming a second leading recess adjacent the second sheet
leading edge of the second thermally conductive sheet; mating the
first leading recess of the first thermally conductive sheet with
the second leading recess of the second thermally conductive sheet;
and following the step of mating, joining the first and second
thermally conductive sheets together to form the recuperator plate
with at least one fluid channel therein, the mated first and second
leading recesses forming a trough extending along a leading edge of
the recuperator plate in a direction substantially parallel to a
longitudinal axis of the recuperator plate.
2. The method of claim 1, further comprising forming the at least
one fluid channel of the recuperator plate with a height that is
non-uniform along the transverse direction and which narrows toward
the leading edge, the at least one fluid channel defining a
cross-sectional profile having said height in a direction
perpendicular to the longitudinal direction and the transverse
direction.
3. The method of claim 1, further comprising forming a plurality of
said recuperator plates and arranging the plurality of the
recuperator plates in a stacked relationship to form an air-to-air
heat exchanger, the recuperator plates being spaced apart to define
therebetween a plurality of interstices adapted to direct
therethrough at least one first stream received at a leading plate
edge of the recuperator plates and a plurality of fluid channels
adapted to direct therethrough at least one second stream to effect
heat exchange between the at least one first stream and the at
least one second stream.
4. The method of claim 1, further comprising forming a first
trailing recess adjacent the first trailing edge of the first sheet
and forming a second trailing recess adjacent the second trailing
edge of the second sheet, and wherein the first and second trailing
recesses are substantially parallel to the first and second leading
recesses and to the longitudinal axis of the recuperator plate.
5. The method of claim 1, further comprising forming a first
plurality of protrusions in the first sheet and a second plurality
of protrusions in the second sheet and conforming a convexly curved
surface of each one of the second plurality of protrusions to a
concavely curved surface of each one of the first plurality of
protrusions prior to joining the first and second leading sheet
edges and the first and second trailing sheet edges.
6. The method of claim 1, further comprising forming the trough on
a suction side of the recuperator plate to contain a leading edge
laminar flow bubble therein and cause re-attachment of laminar flow
immediately downstream of the trough extending along the leading
edge of the recuperator plate.
7. The method of claim 1, wherein the step of joining the first and
second thermally conductive sheets together includes brazing the
first sheet leading edge to the second sheet leading edge and the
first sheet trailing edge to the second sheet trailing edge.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional of U.S. patent
application Ser. No. 13/804,118 filed Mar. 14, 2013, the entire
contents of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates generally to gas turbine
engines and more particularly to recuperators for such gas turbine
engines.
BACKGROUND
[0003] A recuperator may be used to effect heat exchange in a gas
turbine engine. A high performance recuperator typically needs a
large number of recuperator plates made from thin foil, positioned
relative to one another with high accuracy. In particular, a pair
of sheets are generally joined together to form each recuperator
plate and precise positioning of the two sheets is desired when
assembling them into the plate. However, due to the small features
of each sheet, such positioning precision may be difficult to
achieve.
[0004] Conventional assemblies tend to rely on trimming the edges
of the sheets to position the latter. This may result in the plates
becoming wavy during the press forming of each recuperator plate,
thereby reducing the accuracy in the relative positioning of the
sheets. As a result, the overall performance of the recuperator is
negatively effected.
[0005] There is therefore a need for improved gas turbine engine
recuperators.
SUMMARY
[0006] In one aspect, there is provided a method for manufacturing
a recuperator for a gas turbine engine, the method comprising:
forming at least one recuperator plate, the recuperator plate
extending in a longitudinal direction between an upstream and a
downstream end spaced apart along a longitudinal axis, the
recuperator plate extending in a transverse direction between a
leading edge and a trailing edge thereof, each of the leading edge
and the trailing edge extending longitudinally between the upstream
and the downstream edges, the transverse direction being
substantially perpendicular to the longitudinal direction defined
by the longitudinal axis, forming the recuperator plate including:
providing first and second thermally conductive sheets,
respectively having a first sheet leading edge and a first sheet
trailing edge, and a second sheet leading edge and a second sheet
trailing edge; forming a first leading recess adjacent the first
sheet leading edge of the first thermally conductive sheet, and
forming a second leading recess adjacent the second sheet leading
edge of the second thermally conductive sheet; mating the first
leading recess of the first thermally conductive sheet with the
second leading recess of the second thermally conductive sheet; and
following the step of mating, joining the first and second
thermally conductive sheets together to form the recuperator plate
with at least one fluid channel therein, the mated first and second
leading recesses forming a trough extending along a leading edge of
the recuperator plate in a direction substantially parallel to a
longitudinal axis of the recuperator plate.
[0007] In a further aspect, there is provided a method for
manufacturing a recuperator for a gas turbine engine, the method
comprising: forming a first leading recess adjacent a first leading
edge of a first thermally conductive sheet and forming a second
leading recess adjacent a second leading edge of a second thermally
conductive sheet, the first and second thermally conductive sheets
being components of a recuperator plate; mating the first leading
recess of the first thermally conductive sheet with the second
leading recess of the second thermally conductive sheet; following
the step of mating, joining the first and second leading sheet
edges and a first and second trailing sheet edges thereby forming a
recuperator plate, the first and second leading recesses forming a
trough extending along a leading edge of the recuperator plate in a
direction substantially parallel to a longitudinal axis of the
recuperator plate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Reference is now made to the accompanying figures in
which:
[0009] FIG. 1 is a schematic cross-sectional view of a gas turbine
engine;
[0010] FIG. 2 is a partial cross-sectional view of the gas turbine
engine of FIG. 1, showing a recuperator in accordance with an
embodiment;
[0011] FIG. 3 is a cross-sectional view of the recuperator of FIG.
2;
[0012] FIG. 4 is a perspective view of a recuperator segment of
FIG. 3;
[0013] FIG. 5 is a perspective view of a recuperator plate of FIG.
4;
[0014] FIG. 6 is a partial cross-sectional view of the recuperator
segment of FIG. 4;
[0015] FIG. 7 is a close-up view of FIG. 6 showing a laminar flow
in accordance with an embodiment; and
[0016] FIG. 8 is a flowchart of a method for manufacturing a
recuperator in accordance with an embodiment.
DETAILED DESCRIPTION
[0017] FIG. 1 illustrates a gas turbine engine 10 of a type
preferably provided for use in subsonic flight, generally
comprising in serial flow communication, a fan 12 through which
ambient air is propelled, a compressor section 14 for pressurizing
the air, a combustor 16 in which the compressed air is mixed with
fuel and ignited for generating an annular stream of hot combustion
gases, and a turbine section 18 for extracting energy from the
combustion gases. The combustion gases flowing out of the combustor
16 circulate through the turbine section 18 and are expelled
through an exhaust duct 24.
[0018] Although illustrated as a turbofan engine, the gas turbine
engine 10 may alternatively be another type of engine, for example
a turboprop or turboshaft engine, also generally comprising in
serial flow communication a compressor section, a combustor, and a
turbine section, and further including an exhaust duct through
which the hot turbine gases are expelled.
[0019] Referring to FIG. 2, a recuperator 30 extends across the
exhaust duct 24, such that the exhaust gas from the turbine section
18 circulates therethrough. As will be discussed further below, the
recuperator 30 may then use the hot exhaust gas from the engine 10
to heat compressed air exiting from the compressor 14 and/or fan 12
prior to circulation of the compressed air to the combustion
chamber 16. In this manner, the fuel efficiency of the engine 10 is
improved while its infrared signature is minimized.
[0020] Referring to FIG. 3 and FIG. 4, the recuperator 30 comprises
a plurality of recuperator segments 40, which illustratively
function and are connected to the engine 10 independently from one
another. Structural supports 42 may be provided between adjacent
ones of the recuperator segments 40 to provide structural
stability. The recuperator segments 40 are positioned relative to
one another so as to together define the substantially annular
shape of the recuperator 30.
[0021] Each recuperator segment 40 comprises a plurality of
recuperator plates 44 arranged in a stacked relationship along an
axis A. To provide structural stability, the stack may be mounted
on one or more backing members 46, such as a frame, chassis or
endplate, which does not impede the flow of fluid through the
recuperator segment 40.
[0022] Referring to FIG. 5 in addition to FIG. 2 and FIG. 3, each
recuperator plate 44 is elongate and extends along a longitudinal
axis B. It should however be understood that each recuperator plate
44 may have some axial curvature by shaping and/or angling thereof
to introduce some deviation or curvature to the axis B. Each
recuperator plate 44 comprises a leading peripheral edge 48 and a
trailing peripheral edge 50 opposite the leading edge 48. With the
recuperator 30 extending across the exhaust duct (reference 24 of
FIG. 1) of the engine 10, a radial turbine exhaust gas flow 52 is
conducted through the recuperator segments 40 and received at the
leading edges 48 of the recuperator plates 44. The flow 52 may
subsequently progress through the recuperator plates 44 of each
recuperator segment 40, as will be discussed further below, and is
discharged at the trailing edges 50. A flow 53 of a secondary
fluid, such as low-temperature pressurized air output from the
compressor 12, may further be drawn, conducted, or otherwise
received into the recuperator plates 44. Air flow 53 may be
conducted into the recuperator plates 44 in a generally transverse
direction to the exhaust gas flow 52. In particular and as will be
detailed below, the air flow 53 passes through the recuperator
plates 44 in thermal conductive proximity with the exhaust gas flow
52 so as to effect heat exchange therewith. The exhaust gas flow 52
and the air flow 53 are therefore brought closer in temperature
than upon entry to the recuperator 30. The hotter of the two fluid
flows, e.g. the exhaust gas flow 52, may therefore be cooled while
the cooler of the two fluid flows, e.g. the air flow 53, is
heated.
[0023] Referring to FIG. 6 in addition to FIG. 5, each recuperator
plate 44 illustratively comprises a pair of thermally conductive
sheets 54a, 54b in sealed together relation. The sheets 54a, 54b,
may be made of any suitable thermally conductive and suitable
formable material(s), such as metal(s), ceramic matrix composite
material(s), and the like, alone or in any combination(s),
mixture(s), or concentration(s) suitable for providing heat
exchange. The sheets 54a, 54b may be constructed to have a minimal
thickness, thus achieving lightweight design and improved thermal
efficiency. The sheets 54a, 54b may be joined together by welding,
brazing, or any other suitable process.
[0024] A plurality of protrusions or corrugations as in 56a, 56b
are illustratively formed on the surface of each sheet 54a, 54b.
The protrusions 56a, 56b may be provided in a pattern along at
least one dimension (e.g. length, width) of the sheets 54a, 54b so
that the latter have a substantially undulated cross-sectional
profile. Depending on the positioning and pattern of the
protrusions 56a, 56b, the undulations in the cross-sectional
profiles of the sheets 54a, 54b may extend widthwise, lengthwise,
or any other direction. A first substantially elongate concavity or
trough 58a is further formed in the first sheet 54a at the leading
edge 48a thereof while a second concavity 60a is formed in the
first sheet 54a at the trailing edge 50a thereof. Similarly, a
first concavity 58b is formed in the second sheet 54b at the
leading edge 48b thereof while a second concavity 60b is formed in
the second sheet 54b at the trailing edge 50b thereof. Each
concavity 58a, 58b, 60a, 60b extends along the leading and trailing
edges in a direction parallel to the longitudinal axis B. In other
words, the leading edge concavities 58a, 58b are disposed in a
direction substantially transverse to the airflow through the
recuperator plates, along the length of each leading edge of each
recuperator plate. These leading and trailing edge concavities are
disposed and oriented in the sheets 54a, 54b of the plates 44 such
that they are generally parallel to one another. Further, the
leading edge concavities 58a, 58b are disposed such that the
concavities face the suction side of the plates 44 in the
recuperator stack (the suction side being defined as a result of
the hot turbine exhaust stream entering the recuperator stack at a
positive incidence angle). By ensuring that the concavities face
the suction side of the recuperator leading edge 48 of plates 44,
the leading edge laminar bubble that is created is contained in the
trough or concavity 58a, 58b, which energizes the boundary layer
and allows the flow to re-attach immediately downstream of the
trough, as depicted in FIG. 7. This ensures flow turning with
limited pressure loss and increased heat transfer at the leading
edge of the recuperator plates 44.
[0025] In order to form the protrusions 56a, 56b and the concavity
58a, 58b, 60a, 60b, the sheets 54a, 54b may be press-formed, bent,
curled, cut, deformed, tooled, or otherwise machined. In one
embodiment, the concavities 58a, 58b, 60a, 60b are formed during
manufacturing of a given sheet 54a, 54b prior to forming the
protrusions 56a, 56b. As such, the concavities 58a, 58b, 60a, 60b
may serve as a centering and reference feature allowing for high
accuracy in the relative positioning of the sheets 54a, 54b.
Indeed, the concavities 58a, 58b, 60a, 60b provide means for
accurately positioning a pair of sheets as in 54a, 54b relative to
one another when forming each recuperator plate 44 and during
brazing or welding of the plates. As illustrated in FIG. 6, the
sheets 54a, 54b may be positioned in close proximity to one another
so that corresponding concavities 58a, 58b, 60a, 60b nest or
otherwise mate with one another. In particular, a convexly curved
surface (not shown) of each concavity 58a, 60a of the first sheet
54a may be conformed to a concavely curved surface (not shown) of
each corresponding concavity 58b, 60b of the second sheet 54b.
Plate concavities 58 and 60 may then be formed by the mating of a
pair of concavities 58a, 58b, 60a, 60b. In this position, the
protrusions 56a of the first sheet 54a may further nest or be
otherwise conformal fitted with the corresponding protrusions 56b
of the second sheet 54b. Plate protrusions 56 may then be formed by
the conformal fitting of a pair of protrusions 56a, 56b. The
leading edge 48a of the first sheet 54a may then be welded, brazed,
or otherwise attached to the leading edge 48b of the second sheet
54b while the trailing edge 50a of the first sheet 54a is welded to
the trailing edge 50b of the second sheet 54b, thereby forming
brazed areas 62.
[0026] The leading edge concavities 58a, 58b and the trailing edge
concavities 60a, 60b of the recuperator plates 44 also provide an
accurate positioning reference which can be used, once these
concavities or longitudinally extending troughs are created in the
plates, as a reference guide for subsequently performed
manufacturing operations carried out to create the completed
recuperator plates 44, such as forming, trimming, and assembly,
brazing, etc. The performance of the thus formed recuperator
segment (reference 40 in FIG. 3) and accordingly the overall
performance of the engine 10 are therefore improved. The provision
of the concavities 58a, 58b, 60a, 60b further improves the
stiffness of the formed recuperator plate 44 at the leading edge 48
and trailing edge 50 thereof. The geometry of the leading and
trailing edges 48, 50 can therefore be maintained while the rest of
the plate 44 deforms under thermal and/or pressure loads. As such,
buckling of the plate 44 may be prevented.
[0027] When the sheets 54a, 54b are coupled as shown in FIG. 6, a
fluid channel 64 is defined by the spacing between adjacent
surfaces (not shown) of the sheets 54a and 54b. In addition, once
each recuperator plate 44 is formed, the plurality of plates 44 are
then stacked along the axis A, resulting in the fluid channels 64
being stacked in close proximity to one another. In this
configuration, a number of interior compartments or interstitial
layers (more generally "interstices") 66 are further formed between
adjacent recuperator plates 44. The shape of the interstices 66 may
be defined by the shape and spacing between the protrusions as in
56 of adjacent recuperator plates 44. In particular, the
protrusions 56 of adjacent plates 44 may oppose so that each
protrusion 56 of one plate 44 is sized to accommodate a
corresponding recess 68 between adjacent protrusions 56 of an
adjacent plate 44. Each interstice 66 may then be defined by the
spacing between a concavely curved surface (not shown) of a
protrusion 56 of the one plate 44 and a concavely curved surface
(not shown) of a recess 68 between adjacent protrusions 56 of the
adjacent plate 44.
[0028] The fluid channels 64 may be suitable to receive and conduct
therethrough the air flow 53 while the interstices 66 may be
suitable to receive and conduct therethrough the gas exhaust flow
52. In particular, the fluid channels 64 are illustratively sealed
from the external environment, including being sealed from the
interstices 66. The exhaust gas flow 52 can therefore be conducted
through the recuperator 30 without admixture or interminglement
with the air flow 53. As the air flow 53 passes through the fluid
channels 64 in thermal conductive proximity with the exhaust gas
flow 52 passing through the interstices 66, heat exchange is
effected between the air flow 53 and the exhaust gas flow 52. In
addition, due to the undulating pattern of the protrusions 56 on
each recuperator plate 44, an undulating flow path is formed in the
fluid channels 64. Fluid turbulence, and therefore fluid mixing, is
thus increased within the fluid channels 64 to promote heat
exchange between the air flow 53 and the exhaust gas flow 52. It
should be understood that while it may be advantageous in some
embodiments for the fluid channels 64 to conduct a relatively
high-pressure, low-temperature fluid, e.g. the air flow 53, in
comparison to a relatively low-pressure, high-temperature fluid,
e.g. the exhaust gas flow 52, conducted through the interstices 66,
the recuperator 30 is not limited to such usage.
[0029] Referring now to FIG. 7, upon the exhaust gas flow 52 being
received at the leading edge 48 of the recuperator plates 44 and
reaching the concavities 58, laminar bubbles 68 are formed. When
such laminar bubbles 68 form, the gas flow 52 no longer follows the
curvature of the recuperator plates 44 and the laminar boundary
layer separates from the surface of the recuperator plates 44.
Still, due to the residual swirl of the exhaust gas flow 52, the
latter illustratively is received at the leading edges 48 of the
recuperator plates 44 segment 40 at a positive incidence angle (not
shown) such that the laminar bubbles 68 are contained in the
concavities 58. As a result, the boundary layer is energized and
flow re-attachment occurs behind the laminar bubbles 68 immediately
downstream of the concavities 58. The re-attachment of the exhaust
gas flow 52 to the plates 44 then ensures flow turning with reduced
pressure loss and increased heat transfer at the leading edge 48 of
the plates 44. Leading edge aerodynamics on the recuperator segment
40 are further significantly improved, thus improving the overall
efficiency of the recuperator 30.
[0030] Referring to FIG. 8, a method 100 for manufacturing a
recuperator will now be described. The method 100 comprises the
step 102 of forming troughs at the leading and trailing edges of
each one of a plurality of thermally conductive sheets. The next
step 104 may then be to form corrugations in each sheet. The
troughs and corrugations may be formed by at least one of
press-forming, bending, curling, cutting, deforming, tooling, or
otherwise machining the sheets, as discussed above. The next step
106 may then be to mate the troughs of a first sheet to those of a
second sheet in order to position the first sheet relative to the
second sheet. The first and second sheet may then be joined at step
108 by brazing the leading and trailing edges thereof, thereby
forming a recuperator plate. A plurality of the thus formed
recuperator plates may then be stacked at step 110 to form each
recuperator segment of the recuperator.
[0031] The above description is meant to be exemplary only, and one
skilled in the art will recognize that changes may be made to the
embodiments described without departing from the scope of the
invention disclosed. Modifications which fall within the scope of
the present invention will be apparent to those skilled in the art,
in light of a review of this disclosure, and such modifications are
intended to fall within the appended claims.
* * * * *