Embedded turbofan deicer system
09642190 ยท 2017-05-02
Inventors
Cpc classification
F04D29/584
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/047
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
F05D2240/303
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2220/36
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H05B2203/014
ELECTRICITY
F01D5/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2300/611
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H05B2214/02
ELECTRICITY
F05D2220/768
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/324
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F01D15/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D5/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/047
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/58
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01D25/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An embedded turbofan deicer system (ETDS) may eliminate the ingested ice crystal icing problem plaguing high bypass turbofan engines operating at high altitudes near convective tropical storms: icing occurring on the surfaces of the engine's rotating engine spinner, fan blades, low pressure compressor casing and low pressure compressor and causing loss of power and on occasion engine flameouts. The invention supplies electricity to heat these engine parts using at least one reversed permanent magnet electric generator (reversed PMEG) driven by the turbofan's central drive shaft with all parts of the ETDS mounted internal to the engine in presently unused internal spaces without requiring modifications to the existing engine. All electric power produced by the rotating reversed PMEG supplied directly to rotating engine parts requiring heat for deicing. A unique method to deice metal, composite and metal/composite fan blades is included in the invention using electricity from the reversed PMEG.
Claims
1. An air-breathing jet engine comprising: at least one rotatable shaft; and a deicing apparatus, comprising: a reversed permanent magnet electric generator (PMEG) driven by the at least one rotatable shaft, wherein the reversed PMEG has at least one fixed magnet and at least one rotatable winding; an electrical resistive thermal material positioned on at least a portion of the air-breathing jet engine; at least one electrical ground connection connected between the at least one rotatable winding and an aircraft airframe; and at least one electrical connection between the reversed PMEG and the electrical resistive thermal material.
2. The air-breathing jet engine of claim 1, wherein the reversed PMEG is positioned within an interior space in the nose-end of the air-breathing jet engine between the at least one rotatable shaft and a rotatable low pressure compressor casing of the air-breathing jet engine.
3. The air-breathing jet engine of claim 1, wherein the reversed PMEG further comprises a stator having the at least one fixed magnet, wherein the at least one rotatable winding is positioned exterior of the stator.
4. The air-breathing jet engine of claim 3, wherein the at least one rotatable winding is connected to the at least one rotatable shaft of the air-breathing jet engine.
5. The air-breathing jet engine of claim 3, wherein the at least one rotatable winding is connected to a rotatable low-pressure compressor casing of the air-breathing jet engine.
6. The air-breathing jet engine of claim 3, wherein the stator is affixed to a non-rotatable casing of a forward bearing of the air-breathing jet engine.
7. The air-breathing jet engine of claim 1, wherein the at least one electrical connection further comprises: a first electrode positioned on a leading edge of a fan blade of the air-breathing jet engine; and a second electrode positioned on a trailing edge of the fan blade, wherein the electrical resistive thermal material is positioned between the leading edge and the trailing edge.
8. The air-breathing jet engine of claim 7, wherein at least one of the first and second electrodes further comprises a conductive coating formed on the fan blade.
9. The air-breathing jet engine of claim 7, wherein at least one of the first and second electrodes further comprises a conductive coating formed at least partially within the fan blade.
10. The air-breathing jet engine of claim 7, wherein the at least one electrical connection further comprises at least one electrical cable positioned through the fan blade.
11. The air-breathing jet engine of claim 1, wherein the at least one electrical ground connection has at least one grounding cable positioned at least partially through a hollow center of the at least one rotatable shaft.
12. The air-breathing jet engine of claim 1, further comprising at least one of a temperature sensor and an ice detection sensor positioned on the air-breathing jet engine.
13. The air-breathing jet engine of claim 12, further comprising a control system interfaced with the at least one of a temperature sensor and ice detection sensor, wherein the control system controls a quantity of thermal energy produced by the electrical resistive thermal material.
14. The air-breathing jet engine of claim 13, further comprising an electrical switching system in communication with the control system, wherein the electrical switching system controls a distribution of a quantity of electrical power generated by the reversed PMEG to the electrical resistive thermal material.
15. The air-breathing jet engine of claim 1, wherein the portion of the air-breathing jet engine on which the electrical resistive thermal material is positioned further comprises at least one of: an engine spinner; a fan blade; a low-pressure compressor casing; and a low-pressure compressor.
16. The air-breathing jet engine of claim 1, wherein the reversed PMEG further comprises a stator having the at least one fixed magnet, wherein the at least one rotatable winding is positioned interior of the stator.
17. A method of deicing an air-breathing jet engine, the method comprising the steps of: creating a quantity of electrical power with a reversed permanent magnet electric generator (PMEG) driven by at least one rotatable shaft of an air-breathing jet engine, wherein the reversed PMEG has at least one fixed magnet and at least one rotatable winding; sensing a thermal condition of an externally exposed portion of a rotatable fan blade of the air-breathing jet engine; and supplying the quantity of electrical power to an electrical resistive thermal material positioned on the externally exposed portion of the rotatable fan blade of the air-breathing jet engine, whereby a quantity of thermal energy is provided to the externally exposed portion of the rotatable fan blade.
18. The method of claim 17, wherein creating the quantity of electrical power with the reversed PMEG with the at least one rotatable shaft further comprises rotating the at least one rotatable winding connected to the at least one rotatable shaft past a stator having the at least one fixed magnet.
19. The method of claim 17, further comprising controlling supplying the quantity of electrical power to the electrical resistive thermal material with a control system, wherein the control system further comprises an ice detection sensor.
20. The method of claim 19, further comprising controlling a distribution of the quantity of electrical power generated by the reversed PMEG to the electrical resistive thermal material with an electrical switching system in communication with the control system.
21. A system for deicing a turbofan, the turbofan having at least one rotatable shaft connected to a plurality of fan blades, comprising: a reversed permanent magnet electric generator (PMEG) having a stator with at least one fixed magnet and at least one rotatable winding, wherein the at least one rotatable winding is mechanically connected to the at least one rotatable shaft, and wherein the stator is positioned between the at least one rotatable winding and the at least one rotatable shaft; at least one electrical ground connection having a grounding cable connected between the at least one rotatable winding and an aircraft airframe, wherein the grounding cable is positioned at least partially through a hollow center of the at least one rotatable shaft; an electrical resistive thermal material positioned on each of the plurality of fan blades; and at least one electrical connection between the reversed PMEG and the electrical resistive thermal material, wherein the at least one electrical connection has at least one electrode positioned on an edge of each of the plurality of fan blades.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(12) A cross-sectional diagram of a typical prior art turbofan aircraft engine of high bypass ratio 10 is provided in
(13) The forward portion of the typical prior art turbofan aircraft engine of high bypass ratio, where icing is expected, is shown in
(14) The geometry shown in
(15) The reversed PMEG and associated equipment of the Embedded Turbofan Deicer System (ETDS) of the present invention are installed internally in the aircraft's turbofan engine within engine spaces vacant and not presently utilized. Installation of the ETDS of the present invention requires no redesign of the existing engine geometry. As noted in
(16) Both Volume A, 22 and Volume B, 23 are circular symmetric volumes about the engine's central drive shaft. For the following calculation for the electric power requirements for deicing, assuming the engine geometry shown in
(17) The amount of heat and equivalent electric power needed to melt the portion of ice crystals ingested into a turbofan engine and not bypassed through it but passing into the engine's combustion circuit can be calculated when the aircraft's flight conditions, the loading of ice crystals in the atmosphere, the atmosphere's ambient temperature, diameter of the engine's fan blades, and engine's bypass ratio are known. For an aircraft cruising at M=0.82 and 38,000 feet, with an example atmospheric ice crystal loading of 1 gram per cubic meter, an atmospheric temperature of 69.7 F (56.5 C), and having an engine with fan blade diameter of 111 inches (282 cm) and a bypass ratio of 10, the amount of heat required to deice the ice crystals in the combustor circuit is calculated in two parts. One part is the heat (electric power) needed to raise the ice crystals from 67.7 F to 32 F, (56.5 C to 0 C) without melting them (the specific heat part). The second part is the heat (electric power) needed to melt the ice at 32 F (0 C) to water at 32 F (0 C) (the heat of fusion part).
(18) For a 1 gram per cubic meter ice crystal loading, 60.4 kJ/sec (kW sec/sec=kW) of heat is found to be required to melt the ice crystals. If a reversed PMEG of radial magnetic flux type with Lexus automobile motor volume density of 6.59 kW/L (186 kW/ft.sup.3) and a 2.46 kW/kg (167 lbs/ft.sup.3) specific power density is then chosen for the example calculation, the corresponding volume occupied by the reversed PMEG is 0.32 ft.sup.3 and its weight is 54.2 pounds (24.61 kg). At 1 gram per cubic meter loading, the volume occupied by the reversed PMEG is only 3.1% of the 10.4 cubic feet volume available in Volume A, 22, of a GEnx sized turbofan engine.
(19) For the ice crystal loadings of interest, ranging from 3 grams per cubic meter to 9 grams per cubic meter, the heat required for deicing at 3 grams per cubic meter ice crystal loading is 181 kJ/sec (kW), the volume occupied by the reversed PMEG is 0.96 ft.sup.3, its weight 163 pounds and occupying 9.3% of the available Volume A, 22 while at 9 grams per cubic meter ice crystal loading, 489 kJ/sec (kW) of heat is required, the volume occupied by the reversed PMEG is 2.9 ft.sup.3, its weight 487 pounds and occupying 27.9% of Volume A. From these results, it can be seen that the required electric power for deicing, over the range of ice crystal loading of interest, can be generated by a radial magnetic flux reversed PMEG utilizing only a small portion of Volume A, 22, and having a reasonable weight. Further, a switch from a radial magnetic flux reversed PMEG to an axial magnetic flux reversed PMEG implies further reductions in volume requirements and reduced generator weights by at least a factor of two more. The results also indicate that Volume B, 23 is not needed to house the reversed PMEG and is available to house other parts of the ETDS.
(20) If Volume A, 22 is partially filled with reversed PMEGs and Volume B, 23, of the present invention is not needed for storage of reversed PMEGs and is empty, the electric switches of the electric switching subsystem can be mounted within the remaining free volume in Volume A, 22 and in Volume B, 23 rather than in the engine spinner. The advantage of this arrangement is that it reduces the lengths of heavier electric cabling used between the reversed PMEG generators and thence to the electric switches and back to the heating elements in comparison to a design which has filled Volume A, 22 completely with reversed PMEGs. If Volume A, 22 is completely filled with reversed PMEGs, it would have required that the heavier electric cabling run first from the reversed PMEGs in Volume A, 22, and Volume B, 23 (if used), to electric switches in the engine spinner and thence back to the heating elements.
(21) A drawing illustrating the shape of a prior art fan blade, as viewed from a forward oblique location, is provided in
(22) The reversed PMEG of the present invention differs in principal from what is normally known as a conventional PMEG. As noted in drawings
(23) The reversed PMEG of the present invention differs from a conventional PMEG and a layout of it is provided in
(24) A drawing of a single reversed PMEG of the present invention, designed to be mounted in Volume A, 22 of
(25) The example reversed PMEG of the present invention, shown in
(26) To install a reversed PMEG of the present invention in volume B, 23, of
(27) The present invention uses electric heat to melt ice forming on turbofan engine fan blades of metal material or composite material. Metal fan blades for the present invention,
(28) On a prior art titanium fan blade, the leading edge electrode, 71, of the present invention is formed by adding a conductive coating on the titanium leading edge surface. The trailing edge electrode, 72, and the resistive surface material, 73, between the electrodes also accomplished by adding metal coatings to the blade's surface: the metal coatings forming electrodes, 71, and 72, and that forming the resistive coating, 73 having different electric conductivities.
(29) To convert a prior art composite fan blade strengthened with a titanium or stainless steel leading edge,
(30) To heat the modified prior art composite fan blade, the embedded resistive material, 83, between the two embedded electrodes, 81, and 82, is incorporated in one of a variety of ways. Embedded resistive materials include metal mesh, expanded foil and other approaches previously developed and proven as lightning strike protection for composite materials in aircraft and adapted to the present invention by tailoring them to have the proper value of resistance for the heating application. Other candidate resistive materials are those formed with epoxy compounds of desired resistivity or by the addition of resistive film. Candidate resistive films include films previously developed and used as a radiant underlayment floor heating film in residential construction.
(31) An example of the route followed by electric cables of the ETDS system, added to a prior art turbofan engine to form the ETDS deice system of the present invention, is provided in
(32) The example cable route depicted in
(33) The manner in which temperature and ice detection sensors are installed at various locations on the engine spinner, fan blades and compressor and compressor casing is shown in
(34) A block diagram of the ETDS system is provided in
(35) The portion of electric power from the reversed PMEG, 112, to the electric power converter, 113, is then conditioned as required to power the operation of the temperature receiver, 116, control subsystem, 115, and ice detection receiver, 117. Based on information received by the control subsystem, 115, from the temperature receiver, 116, and the ice detection receiver, 117, the control subsystem actuates or deactivates electric switches in the electric switch unit, 118, to supply electric power to engine spinner heaters, 119, fan blade heaters, 120, and low pressure compressor casing and low pressure compressor heaters, 121. Separately, temperature and ice detection instrumentation in the engine spinner, 122, fan blades, 123, pressure compressor casing and low pressure compressor, take measurements and relay them to the control subsystem, 115, via the temperature receiver, 116, and via the ice detection receiver, 117. The temperature sensor measurements from the engine spinner, fan blades, low pressure compressor casing and low pressure compressor are carried to the temperature receiver via cables, 125, 126, and 127, respectively. The ice detection measurements from the engine spinner, fan blades, low pressure compressor casing and low pressure compressor and are carried back to the ice detection receiver via cables, 128, 129, and 130, respectively. Electrical connections (not shown) between the ETDS, installed in the engine, and the cockpit allow the pilots to manually turn the ETDS on or off should they wish to do so or in response to an emergency arising in the ETDS during its operation.
(36) The forgoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in the light of this disclosure. It is intended that the scope of the invention be limited not by this detailed description but rather by the claims appended hereto.