GAS TURBINE ENGINE SYSTEM WITH MIXED FLOW AUXILIARY POWER UNIT
20230193833 ยท 2023-06-22
Inventors
- Timothy Unton (Avon, IN, US)
- Kirk C. Lefort (Avon, IN, US)
- Paul K. Johnson (Ft. Wayne, IN, US)
- Andrew J. Eifert (Indianapolis, IN, US)
Cpc classification
F05D2260/213
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/601
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/232
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2260/606
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C7/185
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2270/3015
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C6/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2270/3011
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F05D2220/50
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02C9/18
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02C6/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A bleed air control system is configured to vary the air pressure at the inlet of a gas turbine engine. The bleed air control system includes a first gas turbine engine configured to provide bleed air, a second gas turbine engine acting as an auxiliary power unit, and a bleed air control system configured to selectively provide bleed air from the first gas turbine engine to the second gas turbine engine.
Claims
1. A gas turbine engine system comprising a first engine that includes a first compressor, a first combustor, and a first turbine, a second engine that includes a second engine core and an air flow mixer, the second engine core including a second compressor, a second combustor, and a second turbine, the air flow mixer configured to receive a flow of ambient air and combine the flow of ambient air with compressed air to form a combined air flow, and further configured to direct the combined air flow into the second engine core, and a bleed air control system configured to control an inlet pressure of the second compressor, the bleed air control system including a conduit, a flow control valve, and a controller, the conduit configured to direct the compressed air from the first compressor to the air flow mixer, the flow control valve fluidly connected with the conduit, the flow control valve configured to selectively vary the flow of compressed air through the conduit, and the controller programmed to adjust the flow control valve in response to an inlet pressure of the second compressor being less than a predetermined value so that a pressure of the combined flow that is directed into the second engine core allows the second engine core to be operable in a low ambient pressure environment.
2. The gas turbine engine system of claim 1, wherein the air flow mixer is a gas jet ejector, the gas jet ejector configured to use the compressed air from the first compressor as a motive fluid to create a vacuum and pull ambient air into the gas jet ejector and create the combined flow directed into the second engine core.
3. The gas turbine engine system of claim 2, wherein the gas jet ejector includes a nozzle, and an ambient air inlet arranged circumferentially around the nozzle, the nozzle receives the flow of compressed air and the ambient air inlet receives the ambient air.
4. The gas turbine engine system of claim 1, wherein the air flow mixer is an inlet for ambient air and a check valve in fluid connection with the conduit, the check valve configured to direct the compressed air flow into the ambient air inlet.
5. The gas turbine engine system of claim 1, wherein the second engine includes a back pressure regulator downstream of the second engine core, the back pressure regulator configured to vary a pressure of an exhaust air of the second engine.
6. The gas turbine engine system of claim 1, wherein the bleed control system further includes a heat exchanger fluidly connected with the conduit, the heat exchanger configured to remove heat from the compressed air.
7. The gas turbine engine system of claim 6, wherein the heat exchanger is configured to receive ambient air for removing the heat from the compressed air.
8. The gas turbine engine system of claim 6, wherein the first engine further includes a fan, and the heat exchanger is configured to receive air from the fan for removing heat from the compressed air.
9. The gas turbine engine system of claim 1, wherein the controller is programed to vary the flow control valve and the back pressure regulator based on a difference between the pressure at an inlet of the second compressor and a reference pressure value on a predetermined pressure schedule of the second gas turbine engine.
10. The gas turbine engine system of claim 1, wherein the first compressor further comprises an intermediate-pressure compressor section having a first port fluidly connected to the conduit, a high-pressure compressor section having a second port fluidly connected to the conduit, and wherein the controller is programmed to selectively open one of the first port and the second port based on a predetermined pressure versus flow ratio of the first compressor stored on the controller.
11. A gas turbine engine system comprising a first engine that includes a first compressor, a first combustor, and a first turbine, a second engine that includes a second engine core and an air flow mixer, the second engine core including a second compressor, a second combustor, and a second turbine, and the air flow mixer positioned at the inlet of the second engine core, and a bleed air control system including a conduit, a flow control valve, and a controller, the conduit connecting the first compressor to the air flow mixer, the flow control valve fluidly connected with the conduit, and wherein the controller is programmed to adjust the flow control valve in response to an inlet pressure of the second compressor being less than a predetermined value.
12. The gas turbine engine system of claim 11, wherein the air flow mixer is a gas jet ejector.
13. The gas turbine engine system of claim 12, wherein the gas jet ejector further includes an ambient air inlet and wherein compressed air from the first compressor and ambient air enter the ejector coaxially, the compressed air passing through a nozzle positioned radially inward of the ambient air inlet.
14. The gas turbine engine system of claim 11, wherein the air flow mixer is an inlet for ambient air and a check valve in fluid connection with the conduit.
15. The gas turbine engine system of claim 11, wherein the second engine includes a back pressure regulator downstream of the second engine core.
16. The gas turbine engine system of claim 11, wherein the bleed control system further includes a heat exchanger fluidly connected with the conduit.
17. The gas turbine engine system of claim 16, wherein the heat exchanger receives ambient air.
18. The gas turbine engine system of claim 16, wherein the first engine further includes a fan, and the heat exchanger receives air from the fan.
19. The gas turbine engine system of claim 11, wherein the first compressor further comprises an intermediate-pressure compressor section, a port of the intermediate-pressure compressor fluidly connected to the conduit, a high-pressure compressor section, and a port of the high-high pressure compressor fluidly connected to the conduit, and wherein the controller is programmed to selectively open the port of the intermediate-pressure compressor and the port of the high-pressure compressor based on a predetermined pressure vs flow ratio of the first compressor.
20. A method of controlling a gas turbine engine system, the method comprising compressing a first air stream using a first compressor of a first gas turbine engine to provide a first compressed air stream, compressing a second air stream using a second compressor of a second gas turbine engine, determining an inlet pressure of an inlet of a second compressor, and directing a portion of the first compressed air stream to the inlet of the second compressor in response to the inlet pressure of the second compressor being lower than a predetermined value.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0024]
[0025]
[0026]
[0027]
[0028]
[0029]
DETAILED DESCRIPTION OF THE DRAWINGS
[0030] For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to a number of illustrative embodiments illustrated in the drawings and specific language will be used to describe the same.
[0031] A gas turbine engine system 10 for producing propulsion and power for an aircraft 8 is shown diagrammatically in
[0032] In the illustrative embodiment, the aircraft 8 includes a number of gas turbine engines for propelling the aircraft 8; however, only the first gas turbine engine 12 is configured for delivering the compressed bleed air 78 to the second gas turbine engine 14. In other embodiments, any number of the propulsive gas turbine engines of the aircraft 8 or other unpictured APUs may be connected with and configured to deliver compressed bleed air 78 to the auxiliary power unit/second gas turbine engine 14.
[0033] In this embodiment shown in
[0034] The second gas turbine engine 14 includes a compressor 32, a combustor 34, a turbine 36, a gearbox 38, an electric generator 40, and an air flow mixer 42 as shown in
[0035] The air flow mixer 42 is fluidly connected with the first gas turbine engine 12 via the bleed air control system 16 as shown in
[0036] The bleed air control system 16 is configured to selectively vary the flow of compressed bleed air 78 from the compressor 18 of the first engine 12 to the air flow mixer 42 and compressor 32 of the second engine 14. The bleed air control system 16 includes an optional pre-cooler 62, a flow control valve 64, an optional heat exchanger 66, a back pressure regulator 68, a controller 70, and conduit 80. The compressed bleed air 78 is bled through conduit 80 from the compressor 18 of the first engine 12 and passes through the pre-cooler 62 if one is present. The pre-cooler 62 uses ambient air or other heat sink to remove heat from the bleed air 78 before it enters the flow control valve 64. The pre-cooler 62 may already be present for the first gas turbine engine 12 and easily incorporated into the bleed control system 16. The compressed bleed air 78 may be bled through one or both of a first port 25 on the intermediate-pressure compressor 24 and a second port 27 on the high-pressure compressor 26 into the conduit 80.
[0037] The flow control valve 64 is configured to open and close selectively to allow the compressed bleed air 78 to move through the conduit 80 from the compressor 18 to the air flow mixer 42 or block the compressed bleed air 78 as suggested in
[0038] The heat exchanger 66, if present, uses ambient air or another heat sink such as fan air to remove heat from the compressed bleed air 78 moving through the bleed air control system 16 as suggested in
[0039] The back pressure regulator valve 68 is located downstream of the second gas turbine engine 14 as shown in
[0040] In some embodiments, the second engine 14 is located within a pod 74 as shown in
[0041] A detailed view of the gas turbine engine 14 is shown in
[0042] The compressed bleed air 78, when delivered to the air flow mixer 42, enters the compressed air inlet 44 and passes through the nozzle 48, which converts some of the pressure in the compressed bleed air 78 to velocity. The air that exits the nozzle 48 acts as a motive fluid and creates a vacuum which pulls or entrains the lower pressure ambient air coming through the ambient air inlet 46 to form a combined flow. This combined flow has a higher pressure than just the ambient air alone and passes through the diffuser 50, which increases the pressure of the air entering the compressor 32 of the second gas turbine engine 14. The pressure sensor 52 measures the pressure of the air at the exit of the diffuser 50 and the inlet of the compressor 32. The pressure at compressor 32 may allow the second gas turbine engine 14 to operate at higher altitudes than it would be capable of operating at using ambient air alone in a low ambient pressure environment.
[0043] Another embodiment of an air flow mixer 242 is shown in
[0044] The controller 70 varies the amount of compressed bleed air 78 delivered to the air flow mixer 42 as suggested in
[0045] The controller 70 is further configured to adjust the back pressure regulator valve 68 according to a pressure schedule stored in the memory 71 to vary the exhaust air pressure at the exhaust duct 76 to maintain a desired pressure ratio across the second gas turbine engine 14. This may be helpful because the low ambient pressure environment may cause the exhaust air pressure to be lower than expected at the exhaust duct 76 due to the bleed air control system 16 raising the pressure at the inlet of the compressor 32.
[0046] In configurations such as the one shown in
[0047] Maintaining these desired pressures allows the second gas turbine engine 12 to run at more optimal conditions and to accommodate the load on the electric generator 40 when aircraft 8 is at high altitudes and the second gas turbine engine 12 is functioning as an electronic auxiliary power unit (e-APU). An e-APU functions similarly to a standard aircraft auxiliary power unit, except that it may be configured to only produce electricity and not to provide compressed air to the aircraft or other engines.
[0048]
[0049] In a step 302, the controller 70 checks the state of the second gas turbine engine 14 to determine if the second gas turbine engine 14 is either on (operating) or in start mode. The controller 70 may make this determination by querying the engine's controller or receive signals from speed/pressure sensors. If the second gas turbine engine 14 is either not on or in the start mode, the controller 70 directs the flow control valve 64 to close as in a step 304. If the controller 70 determines that the second gas turbine engine 14 is either on or in start mode, the controller will move to a step 306. In step 306 shown in
[0050] In step 308 shown in
[0051] In step 314 shown in
[0052] In step 318 shown in
[0053] In step 322 shown in
[0054] Modern aircraft are becoming increasingly more electric, with electrically driven compressors, electric in-flight entertainment and electro-mechanical actuators instead of hydraulic actuators. These loads may exceed the power generation capability of generators mounted to the primary propulsion engines of the aircraft. Therefore, there may be a desire to generate additional electricity from auxiliary power units, which when only generating electrical power may be called an e-APU. Auxiliary power units are typically much smaller gas turbines used for main engine starting and some supplemental power generation while the main propulsion engines are off. An electric APU or e-APU would only supply electricity rather than bleed air.
[0055] To reduce cost, it may be desirable to utilize existing, certified gas turbine engines for this purpose. This creates a challenge in that the most suitable gas turbines from a size perspective are typically helicopter engines or general aviation engines that are not certified for or capable of operating at the high altitudes of modern commercial airliners. In addition, these engines may experience severe lapse rates in their power output capability as the altitude increases, limiting the amount of electric power than can be supplied.
[0056] A proposed solution to this challenge in accordance with the present disclosure may be to combine ambient high altitude, low pressure and low temperature air with some compressor bleed air from the main propulsion engines to feed the inlet stream of the e-APU engine. A gas jet ejector may be proposed for mixing the low- and high-pressure streams to create a medium-pressure stream acceptable to the e-APU gas turbine engine. Other methods may also be possible to combine the streams such as a rapid open-close check valve on the compressed bleed air stream
[0057] An advantage of this arrangement is that lower altitude conditions can be simulated at the inlet of the e-APU. Using compressor bleed air from the main propulsion engine can reduce the operating line increasing surge margin for the main engine depending at the offtake location, whereas the more conventional means of extracting shaft power directly has the effect of decreasing surge margin for the main engine. In the case of a 3-spool engine with an intermediate-pressure (IP) compressor exit bleed, this may increase surge margin on the IP compressor but decrease surge margin on the high-pressure (HP) compressor. By varying the mix ratio of compressor bleed air and ambient air to the e-APU it may enable the e-APU to operate with no compressor bleed air up to its maximum envelope and then as altitude is increased additional compressor bleed air can be fed to the e-APU.
[0058] Optionally, since the e-APU's power output may decrease as the altitude is increased, compressor bleed air can be selectively added even while within the e-APU's nominal operating altitude to increase the power capability. A notional planned control algorithm for the e-APU could be as shown in the flowchart of
[0059] Aircraft main engines are typically designed to provide more high-pressure bleed air than the aircraft needs to account for failure scenarios. The present disclosure uses the excess bleed air from main propulsion engines to drive an ejector that feeds the inlet of a second gas turbine engine used for power generation. At lower altitudes no bleed air is taken, and then the scheduled bleed air increases with altitude. Hot bleed air is mixed with cold ambient air to provide an acceptable inlet temperature for the power-producing gas turbine engine. The power-producing gas turbine engine is able to remain within its certified operational envelope using the higher pressure air produced by the ejector. The present disclosure also includes an engine exhaust backpressure regulator to keep exhaust conditions acceptable for engine operation.
[0060] While the disclosure has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as exemplary and not restrictive in character, it being understood that only illustrative embodiments thereof have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.