ULTRA-MICRO GAS TURBINE GENERATOR
20230272742 · 2023-08-31
Inventors
Cpc classification
F05D2250/82
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D1/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02K1/002
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T50/60
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F05D2230/31
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C3/045
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2240/61
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2220/76
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02K7/1823
ELECTRICITY
F01D5/085
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2230/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02C3/045
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D15/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A novel structural arrangement for the various components of an Ultra-Micro Gas Turbine Generator, based on a single part impeller element which comprises the compressor, the turbine and the electrical generator core in a single annular structure, produced as a single piece by an additive manufacturing process. The single annular structure has a hollow shell structure, with a supporting structure within in. The internal hollow space of the shell structure provides for a flow of cooling air from the outside through the internal space, for cooling the turbine region of the impeller. This air flow could be assisted by the use of internal blades, which can also serve as the supporting structure to increase the strength of the shell structure. The air flow can either be ejected at the center of the turbine, or can provide a high pressure supply for air bearings of the impeller element.
Claims
1. A gas turbine system, comprising: an impeller element having a hollow shell structure on which is formed a compressor element and a turbine element, the impeller element being constructed of a single piece of material; at least one bearing configured to support the impeller element such that it can rotate about its axis; and a combustion chamber external to the impeller element, and adapted to receive a fuel/air mixture whose combustion products are directed through the turbine, wherein the shell structure is adapted to enable an internal flow of air within the impeller element.
2. The gas turbine system according to claim 1, wherein at least part of the internal flow of air inside the impeller element is adapted to provide cooling to the turbine region of the impeller element.
3. The gas turbine system according to claim 1, wherein at least part of the internal flow of air inside the impeller element is emitted therefrom to provide cooling to at least one bearing on which the impeller element rotates.
4. The gas turbine system according to claim 1, wherein the shell structure includes support elements configured to provide mechanical strength to the structure while not significantly impeding air flow through the shell structure.
5. (canceled)
6. The gas turbine system according to claim 1, wherein the impeller element further comprises an electricity generator core, such that the system can generate electricity.
7. The gas turbine system according to claim 1, further comprising an exhaust gas nozzle to generate directional thrust from the kinetic energy of exhaust flow from the turbine.
8. The gas turbine system according to claim 1, wherein the shell structure has an array of blades formed internally, the blades being aligned such that the cooling air is circulated through the shell structure.
9. (canceled)
10. The gas turbine system according to claim 8, wherein the shape of the cavity of the shell structure, and the position and geometry of the blades are selected to control the modal frequency of the structure when rotated.
11. The gas turbine system according to claim 22, further comprising a helical groove compressor formed within a shaft of the shell structure, such that pressurized cooling air is pumped from outside through the shell structure.
12. (canceled)
13. The gas turbine system according to claim 1, wherein the impeller element further comprises at least one magnetic element, and wherein a static conductive element is disposed in close proximity to the at least one magnetic element, such that rotation of the impeller induces eddy currents in the static conductive element, causing compensation for axial forces generated by the rotating compressor and turbine.
14. The gas turbine system according to claim 1, wherein the hollow shell structure is generated by an additive manufacturing method.
15. The gas turbine system of claim 14, wherein the additive manufacturing method is enabled by planning the blades of the turbine element to have a planar end surface.
16. The gas turbine system according to claim 1, wherein the hollow shell structure is constructed either of a ceramic material, or of a high-strength nickel alloy.
17. A method of forming elements of a gas turbine, the method comprising: forming an impeller element comprising a turbine and a compressor formed on a hollow shell structure, the hollow shell structure enabling a flow of air inside the impeller element, wherein the impeller element is formed by an additive manufacturing method.
18. The method according to claim 17, wherein the hollow shell structure is formed either of a ceramic material, or of a high-strength nickel alloy.
19. The method according to claim 17, wherein the additive manufacturing method is characterized by the impeller element having a planar end surface at the turbine end of the hollow shell structure.
20. (canceled)
21. The method according to claim 17, wherein the flow of air inside the impeller element is drawn from outside the impeller element to pass through the impeller element.
22. The gas turbine system according to claim 1, wherein the shell structure has at least one opening adapted to enable a flow of air from outside the impeller element to pass through the impeller element.
23. The gas turbine system according to claim 22, wherein at least part of the flow of air from outside passing through the impeller element is adapted to provide at least one of (i) cooling to the turbine region of the impeller element or (ii) support and cooling to at least one air bearing on which the impeller element rotates.
24. The gas turbine system according to claim 22, further comprising an array of blades formed internally within the shell structure, the blades being aligned to generate suction such that the flow of air is drawn into the shell structure through an opening in the hollow structure.
25. The gas turbine system according to claim 22, further comprising an opening in the central part of the turbine region of the hollow shell structure, such that the turbine exhaust flow generates suction to draw the flow of cooling air through the hollow shell structure.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which:
[0040]
[0041]
[0042]
[0043]
[0044]
[0045]
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[0047]
DETAILED DESCRIPTION
[0048] Reference is now made to
[0049] The solutions to at least some of the technical problems solved can be seen in the details of
[0050] A major application for the devices of the type shown in
[0054] Further to the above overview in
[0055] As mentioned in the Background section, in order to achieve the desired specific energy (the energy output per unit weight of the device, typically measured in Watt-Hours/kg), the rotating shaft assembly must spin at a very high speed, ranging up to the order of 500,000 rpm or even more. This presents severe technical difficulties and mandates the creation of novel rotor-dynamic solutions to achieve these goals.
[0056] In the first place, because of the need for minimal dimensions, both in the interest of compactness, but also in order to shift the natural bending frequencies beyond operational excitations, all three active components of the presently disclosed UMGT, namely, the compressor, the turbine and the generator, are constructed as a unitary element from a single piece of material. This obviates the need to attach separate components, each manufactured for ease of construction and maximum efficiency, as is done in large scale gas turbine generator installations, and as used in prior art UMGT devices. The problems and additional hardware required for attachment of such tightly dimensioned miniature components, which has been one of the reasons for the failure of prior art UMGT generators to become commercially viable, is thereby obviated. In the presently disclosed devices, such a unitary construction is achieved by manufacturing all of the three rotary components on a single-piece rotary impeller, thereby avoiding the need for any connecting elements to attach the three components to each other.
[0057] Because of the high temperatures generated in the turbine region, it is necessary to use a heat resistant ceramic material for constructing the rotary impeller. One suitable material is Silicon Nitride, which can withstand over 1200° C. Another ceramic material for construction of the rotary impeller, is zirconia, since it has lower heat conduction, enabling isolation of the heat of the turbine from the compressor and generator, both of which should be kept as cool as possible. Alternatively, a high-strength Nickel alloy, such as Inconel, Hastelloy, or similar can be used, as such alloys withstand high temperatures of over 1,000° C. while maintaining their strength. The separate components of prior art UMGT devices have previously been manufactured by additive manufacturing methods. The length and complexity of the shape of the single-piece rotary impeller of the present application can advantageously be achieved by use of Lithographic-based Ceramic Manufacturing (LCM). This manufacturing process currently allows 3D-printing of Zirconia, Alumina, and Silicon Nitride, all of which are ceramics which withstand very high temperatures. LCM is an additive manufacturing technology based on digital light processing (DLP) of photopolymers. Details of the process can be shown in the article entitled “LCM -Technology” published by Lithoz GmbH, of Vienna Austria, which can be found at http://www.lithoz.com/en/additive-manufacturing/lcm-technology.
[0058] As described in the Lithoz article, a transparent resin holds the raw material, which is a slurry consisting of the ceramic powder and a light-sensitive photopolymer, which solidifies when exposed to ultra violet light. To create a new layer of solid material, the build platform moves up, a wiper establishes a thin film of slurry and a mask pattern is projected onto the bottom of the resin. The mask may be generated by an array of micro mirrors which function as pixels irradiating incremental spots on the build plate by reflecting the light source. If a certain mirror is activated, immediate polymerization is triggered, and the slurry film is solidified at the desired location. Thus, an incremental layer of a three-dimensional geometry is generated. Successive layers are solidified, until the ceramic green body is built. LCM therefore offers desirable geometric flexibility, allowing cavities and undercuts, which cannot be achieved with conventional manufacturing technologies. Layer heights can be as small as 10 microns, while printing resolution currently available reaches as little as 32 microns. As all pixels of the build plane are processed at the same time, it is possible to print multiple parts with different geometry during one printing process. The technology is specifically advantageously applied to small scale parts.
[0059] After 3D printing the green body, the photopolymer residuals which operate as binder, are removed in the de-binding process by curing the parts at an elevated temperature. Thereafter, the parts are sintered, which results in a high density and high surface finish, typically as good as 0.5 microns. Parts printed with LCM technology can achieve the same material properties as injection molded parts. The LCM process for the manufacture of temperature resistant ceramic parts, offers the following advantages over components manufactured by conventional methods: [0060] 1. The superior material properties of technical ceramics. [0061] 2. Good design freedom. [0062] 3. Substantially reduced costs, since the tools are merely lithographic images. [0063] 4. Parallel printing of different designs. [0064] 5. High quality surface finish. [0065] 6. The agglomeration of material is avoided, hence preventing cracks during de-binding and sintering.
[0066] Reference is now made to
[0067] Reference is now made to
[0068] Reference is now made to
[0069] As mentioned above, the primary cooling function required is for application in the region of the turbine. Material selection for the UMGT rotor device is significantly narrowed due to the high turbine inlet temperatures and internal stresses. Additive manufacturing technology using only steel alloys, at a scale and resolution necessary for a UMGT, is currently limited to materials which can barely endure more than 800° C., or so. High operational temperature Nickel-based alloys, such as Inconel, Hastelloy, or similar, can be used at temperatures of somewhat over 1,000° C., depending on the particular alloy used. Temperatures significantly higher than 800° C. are required for the UMGT turbine region, and hence the use of ceramic additive manufacturing. With conventional manufacturing technology, active cooling of turbine blades has not been achieved for devices of this scale. It is the ability of additive manufacturing to produce complex geometries within cavities, even using ceramic materials, that enable the UMGT configurations of the present disclosure, inter alia, to overcome this temperature challenge.
[0070] Successful turbine cooling can be achieved by the novel methods and structures of the present disclosure, in one of two ways. In the exemplary rotor body shown in
[0071] The cooling embodiment shown in
[0072]
[0073] One possible location for such air bearings could be around the girth 53 of the cavity section of the impeller, which would appear to be a naturally useful location, being situated in the central region of the rotating body, and therefore most supportive to prevent bending modes which would limit high rotational speed performance. Additionally, that is the location from which the pressurized air would be emitted from the air flow escape holes 52, which would be directly into the region of support surface 53 of the air bearing. Because of the extremely high rotational speed of the impeller, and the very small gap in the bearing, such air bearings may be highly susceptible to radial weight distribution of the rotor, thereby limiting the rotary speed achievable before the first bending mode threshold is crossed. Therefore, the exemplary implementation of the UMGT shown in
[0074] Since the UMGT is a static engine, there is a need to stabilize the rotor axially, in order to avoid unnecessary wear on the bearings arising from the axial thrust generated by the rotating compressor and turbine elements. This requirement is generally unimportant in an aero-jet engine whose whole function is to provide axial thrust in one direction. In larger scale gas turbine engines, when axial stability is important, a balance piston or labyrinth seal, driven by a small level of bleed air, is commonly used to provide axial thrust compensation. However, such a construction is problematic in the very small scale UMGT devices described, such that an alternative axial thrust compensation method must be used. Reference is therefore made to
[0075] However, any of these systems involve electronic thrust measurement, an electronic feedback circuit and a mechanical motion system, all of which increase the complexity of the device. As an alternative, axial thrust compensation system based on eddy-current induction into a static conductive element can be used in the present devices. In the UMGT, the bearings have to carry the axial load resulting from the axial force induced by pressure difference in compressor and turbine. In small scale gas turbines, higher rotational speeds are necessary and additionally, scale effects result in enhanced magnetic forces. These two phenomenon can be utilized for this type of thrust compensation. Several magnets or a single sectioned magnet are attached to the impeller shaft, such that at high speed, an alternating magnetic field is established which induces eddy currents into a conductive stator located in proximity to the rotating magnet or magnets. The eddy currents are used to generate an opposing magnetic field and hence axial thrust compensation to the rotating impeller. This arrangement leads to axial thrust compensation that is proportional to operating speed, and since operating speed is proportional to compressor-turbine pressure difference, which determines the level of the axial thrust, the system is self-regulating, and requires no feedback circuitry or axial moving parts.
[0076] Finally, reference is made to
[0077] It is appreciated by persons skilled in the art that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the present invention includes both combinations and subcombinations of various features described hereinabove as well as variations and modifications thereto which would occur to a person of skill in the art upon reading the above description and which are not in the prior art.