Unitary conduit for transporting fluids and method of manufacturing

The present invention relates generally to fluid distributors, and more specifically to elemental fuel distributors for transporting fuel to fuel nozzles used in gas turbine engines.

Turbine engines typically include multiple fuel nozzles to supply fuel to the engine's combustor. Fuel is introduced from the fuel nozzle at the front end of the burner in the form of a very fine spray. Compressed air flows around the fuel nozzles and mixes with the fuel to create an air-fuel mixture, which is ignited by the burner. Due to the limited fuel pressure available and the wide range of required fuel flow rates, many fuel injectors include a pilot nozzle and a main nozzle, only the pilot nozzle is used during start-up, and the output is high. Both nozzles are used during operation. The flow to the main nozzle is reduced or stopped during start-up and low power operation. Such an injector can more accurately control the fuel flow and guide the fuel injection more accurately according to a specific combustion requirement, so that it can burn more efficiently and cleanly than a single nozzle fuel injector. .. The pilot nozzle and main nozzle can be housed in the same nozzle assembly or can be supported in another nozzle assembly. Also, these dual nozzle fuel injectors can be configured to allow further control of the fuel for the dual combustor, resulting in even higher fuel efficiency and reduction of harmful emissions. The temperature of the ignited air-fuel mixture can reach above 3500 ° F (1920 ° C). Therefore, it is important that the fuel supply conduits, channels and distribution systems are virtually leak-free and protected from flames and heat.

Continuous exposure to high temperatures during the operation of the turbine engine for a long period of time can induce thermal stress on the conduits and fuel nozzles, which can damage the conduits and fuel nozzles and the conduits and fuel. It may adversely affect the operation of the nozzle. For example, thermal stress can cause a reduction in fuel flow in the conduit, which can lead to uneven distribution of excess fuel in the turbine engine. Exposure of high temperatures to the fuel flowing through the conduits and orifices of the fuel nozzles can lead to coking of the fuel, which can lead to blockages and uneven flow. To achieve low emissions, modern fuel nozzles require a large number of complex internal air and fuel circuits to create multiple separate flame zones. Fuel circuits may require a heat shield from the internal air to prevent coking, and certain tip regions may need to be cooled and shielded from combustion gases. In addition, long-term continuous operation with damaged fuel nozzles can reduce turbine efficiency, damage turbine components, and / or reduce engine exhaust temperature margins.

By improving the life cycle of the fuel nozzle installed in the turbine engine, the life of the turbine engine can be extended. Known fuel nozzles include delivery and support systems. A delivery system that includes conduits for transporting fluid delivers fuel to the turbine engine and is supported and shielded within the turbine engine by a support system. More specifically, the known support system surrounds the delivery system and is therefore exposed to higher temperatures than the delivery system, which is cooled by the fluid flowing through the fuel nozzles, and has a higher operating temperature. By setting the outer and inner contours and thicknesses, the thermal stress of the conduits and fuel nozzles can be reduced.

Traditional gas turbine engine components, such as fuel nozzles and their associated conduits and distribution systems, are generally expensive to manufacture and / or repair. This is because traditional fuel nozzle designs with complex conduits and distribution circuits for transporting and distributing fuel involve complex assemblies and the joining of more than 30 components. More specifically, the use of brazed joints may increase the time required to manufacture the component, and the need for the proper area to allow the placement of the brazed alloy, unnecessary. The need to minimize the flow of brazing alloys, the need for acceptable inspection techniques to verify brazing quality, and some brazing that can be used to prevent remelting of the previous brazing joint. The fabrication process can be complicated for any of several reasons, including the need to have brazing alloys. In addition, many brazing joints can result in some brazing runs that can make the base metal of the component fragile. The presence of a large number of brazing joints can increase the weight and manufacturing cost of the components, which is not desirable.

<p> Therefore, it transports and distributes fluids, such as liquid fuels for fuel nozzles, which have a simple substance structure to reduce the potential for leaks and other unwanted effects from heat exposure previously mentioned. It would be desirable to have a fluid distributor with complex flow path circuits and conduits for this. To reduce costs, facilitate assembly, and provide protection from adverse thermal environments, it is desirable to have a fluid distributor with a complex shape for the flow path with a single structure. For example, it is desirable to have a manufacturing method that provides a simple structure for a single fluid distributor with a complex three-dimensional shape for transporting the fluid, such as a fuel supply and distribution system for fuel nozzles.</p>

<p> The above need is a method of making a stand-alone distributor, with the steps of determining the 3D information of a stand-alone distributor with at least one channel with an arched portion located within the distributor ring body with an axis. Each slice includes the steps of converting 3D information into multiple slices that define the cross-sectional layer of the single distributor, and the step of forming each layer of the single distributor one after another by melting the metal powder using laser energy. It can be met by exemplary embodiments that provide the method.</p><p> In another aspect of the invention, the distributor comprises a channel with an arched portion located in the distributoring body and is manufactured using a rapid manufacturing process.</p><p> In another aspect of the invention, the elemental fuel distributor comprises a fuel conduit and a distributor and is manufactured using a rapid manufacturing process.</p><p> The subject matter considered to be the present invention is specifically pointed out and explicitly claimed at the conclusion of the specification. However, the present invention can be best understood with reference to the following description along with the accompanying drawings.</p>

<figref num="1">It is the schematic of the gas turbine engine of the high bypass turbofan.</figref><figref num="2">FIG. 3 is an isometric view of a fuel distributor according to an exemplary embodiment of the present invention.</figref><figref num="3">It is a cross-sectional view of the horizontal axis of the fuel distributor shown in FIG.</figref><figref num="4">FIG. 3 is an isometric view of a fuel distributor according to an alternative exemplary embodiment of the present invention.</figref><figref num="5">Fuel distribution shown in FIG. 4 is a horizontal axis cross-sectional view of the data.</figref><figref num="6">FIG. 3 is an isometric view of a fuel distributor according to another alternative exemplary embodiment of the present invention.</figref><figref num="7">It is a cross-sectional view of the horizontal axis near the inlet end of the fuel distributor shown in FIG.</figref><figref num="8">It is a cross-sectional view of the horizontal axis at the intermediate position of the fuel distributor shown in FIG.</figref><figref num="9">It is a cross-sectional view of the horizontal axis near the outlet end of the fuel distributor shown in FIG.</figref><figref num="10">FIG. 3 is an isometric longitudinal sectional view of a fuel distributor according to another exemplary embodiment of the present invention.</figref><figref num="11">FIG. 3 is an isometric view of an exemplary fuel nozzle having a fuel distributor according to an embodiment of the present invention.</figref><figref num="12">It is a partial isometric sectional view of the exemplary fuel nozzle shown in FIG.</figref><figref num="13">It is a partial isometric sectional view of the exemplary fuel nozzle shown in FIG.</figref><figref num="14">It is another isometric view of the exemplary fuel nozzle shown in FIG.</figref><figref num="15">FIG. 6 is an axial sectional view of an exemplary distributor tip of the exemplary fuel nozzle shown in FIG.</figref><figref num="16">It is an isometric view of the exemplary distribution ring shown at the tip of the exemplary distributor shown in FIG.</figref><figref num="17">Another isometric view of the exemplary distribution ring shown at the tip of the exemplary distributor shown in FIG.</figref><figref num="18">FIG. 5 is an isometric cross-sectional view of the tip of an exemplary distributor of the exemplary fuel nozzles shown in FIGS. 14 and 15.</figref><figref num="19">Another isometric view of the exemplary distribution ring shown at the tip of the exemplary distributor shown in FIG.</figref><figref num="20">Another isometric view of an exemplary distributor tip of an exemplary fuel nozzle shown in FIGS. 14 and 15.</figref><figref num="21">FIG. 3 is an isometric view of another exemplary distributor with a single pilot duct.</figref><figref num="22">FIG. 2 is another isometric view of an exemplary distributor with the single pilot duct shown in FIG.</figref><figref num="23">FIG. 2 is an axial cross-sectional view of an exemplary fuel nozzle tip with the exemplary distributor shown in FIG.</figref><figref num="24">FIG. 3 is a partial view of an exemplary fuel distributor flow path and axial cross section of a heat shield.</figref><figref num="25">FIG. 3 is an isometric view of an exemplary distributor with an annular ring.</figref><figref num="26">It is a flow chart which shows the exemplary embodiment of the method of manufacturing a single distributor.</figref>

Next, referring in detail to the drawings showing the same elements with the same numbers throughout the figure, FIG. 1 incorporates a conduit for transporting liquid fuel and an exemplary embodiment of a distributor that distributes fuel within a fuel injector. An exemplary gas turbine engine 10 (high bypass type) is shown in schematic format. An exemplary gas turbine engine 10 has an axial centerline axis 12 passing through it for reference purposes. The engine 10 preferably includes a core gas turbine engine identified by number 14 as a whole and a fan section 16 located upstream from it. The core engine 14 typically includes an overall tubular outer casing 18 that defines the annular inlet 20. The outer casing 18 further surrounds and supports the booster 22 to increase the pressure of the air entering the core engine 14 to the first pressure level. The high-pressure multi-stage axial compressor 24 receives compressed air from the booster 22 to further increase the pressure of the air. Compressed air flows into the combustor 26, where fuel is injected into the compressed air stream, igniting and raising the temperature and energy levels of the compressed air. High energy combustion products flow from the combustor 26 to the first (high pressure) turbine 28 to drive the high pressure compressor 24 via the first (high pressure) drive shaft 30, and then the first drive shaft 30. It flows to the second (low pressure) turbine 32 to drive the booster 22 and the fan section 16 via a second (low pressure) drive shaft 34 that is coaxial with. After driving each of the turbines 28 and 32, the combustion products leave the core engine 14 via the exhaust nozzle 36 to provide at least a portion of the jet propulsion thrust of the engine 10.

The fan section 16 includes a rotatable axial fan rotor 38 surrounded by an annular fan casing 40. It will be appreciated that the fan casing 40 is supported from the core engine 14 by a plurality of substantially radially spaced outlet guide vanes 42. In this way, the fan casing 40 surrounds the fan rotor 38 and the fan rotor blades 44. The downstream section 46 of the fan casing 40 extends over the outer portion of the core engine 14 and defines a secondary or bypass airflow conduit 48 that provides additional jet propulsion thrust.

From a flow perspective, it will be understood that the initial airflow indicated by arrow 50 enters the gas turbine engine 10 through the inlet 52 to the fan casing 40. There are two airflows 50, a first compressed airflow (indicated by arrow 54) that passes through the fan blade 44 and travels through conduit 48, and a second compressed airflow (indicated by arrow 56) that enters booster 22. Divided into.

The pressure in the second compressed air stream 56 increases and enters the high pressure compressor 24 as indicated by the arrow 58. After mixing with the fuel and burning in the combustor 26, the combustion product 60 exits the combustor 26 and flows through the first turbine 28. The combustion product 60 then flows through the second turbine 32 and exits the exhaust nozzle 36 to provide at least a portion of the thrust of the gas turbine engine 10.

Combustor 26 includes a vertical axis 12 as well as an annular combustion chamber 62 coaxial with inlet 64 and outlet 66. As described above, the combustor 26 receives an annular flow of compressed air from the high pressure compressor outlet 69. A part of this compressor exhaust air flows into the mixer (not shown). Fuel is injected from the fuel nozzle tip assembly and mixed with air to form an air-fuel mixture, which is sent to the combustion chamber 62 for combustion. Ignition of the air-fuel mixture is achieved by a proper igniter and the resulting combustion gas 60 flows axially towards and into the annular, first stage turbine nozzle 72. Nozzles 72 include circumferentially spaced nozzle vanes 74 that extend in multiple radial directions to rotate the gas so that the gas flows at an angle and acts on the first stage turbine blades of the first turbine 28. It is defined by an annular flow path. As shown in FIG. 1, the first turbine 28 preferably rotates the high pressure compressor 24 via the first drive shaft 30. The low pressure turbine 32 preferably drives the booster 22 and the fan rotor 38 via the second drive shaft 34.

The combustion chamber 62 is housed in the engine outer casing 18. Fuel is supplied to the combustion chamber by a fuel nozzle, for example, as in the examples shown in FIGS. 11, 12, 13 and 14. The liquid fuel is transported to the fuel nozzle through the conduit, for example, via the single conduit 105 shown in FIGS. 2, 4, 6 and 10. Another conduit 105 that does not have a simple substance structure may be used as an alternative to transport the liquid fuel to the fuel nozzle. A fuel supply conduit, such as the single conduit 105, may be located within the stem 102 and may be coupled to the fuel distributor tip 190. The pilot fuel and main fuel are injected into the combustor 26 by the fuel nozzle tip assembly, for example, as shown in FIGS. 15 and 20. During the operation of the turbine engine, initially pilot fuel is supplied through the pilot fuel passage 153 (see, eg, FIG. 10) during predetermined engine operating conditions such as starting and idling operations. The pilot fuel is discharged from the fuel distributor tip 190 via the pilot fuel outlet 162. When additional power is required, the main fuel is supplied through the main fuel passages 151, 152 (see, eg, FIG. 10) and the main fuel is injected using the main fuel outlet 161.

Figures 15 to 25 show exemplary embodiments of the present invention of the standalone distributor 300. Figures 2-14 show exemplary embodiments of the fuel distributor 100, including the conduit 105 and the standalone distributor 300. The term "single" is used in this application to mean that the relevant components, such as the Distributor 300 described herein, are manufactured as an integral part during manufacture. Therefore, a single component has an integral structure for that component and is different from a component made of a plurality of components that is joined to form a single component.

FIG. 2 shows an isometric view of the fuel distributor 100 according to an exemplary embodiment of the present invention. The exemplary fuel distributor 100 shown in FIG. 2 includes a conduit 105 and a stand-alone distributor 300. The conduit 105 and distributor 300 may have the simple substance structure shown in FIG. 2, which is subsequently manufactured using the methods described herein. Alternatively, the fuel distributor 100 may be made by separately manufacturing the stand-alone distributor 300 and the conduit 105 and combining them using suitable conventional connecting means so that the stand-alone distributor 300 flows and communicates with the conduit 105.

As shown in FIGS. 2-10, the conduit 105 includes one or more channels 108 located within the vessel body 106. The conduit 105 has an inlet end 111 and an outlet end 112. The fluid enters the conduit 105 at the inlet end 111, flows longitudinally 101 towards the outlet end 112, and exits the conduit 105 at the outlet end 112. FIG. 3 shows a cross-sectional view on the horizontal axis of the exemplary single conduit shown in FIG. As shown in FIG. 2, the exemplary single conduit 105 includes an outer contour 140 and a conduit body 106 having a number of channels 108 located within the conduit body 106. The flow path has a cross-sectional shape 120 and an inner contour 141. In the exemplary embodiment shown in FIG. 3, there are four passages, each having a circular cross-sectional shape. As shown in FIG. 2, the channels may have different dimensions. For example, in the exemplary embodiment shown in FIG. 2, two outer passages 155 and 157 are pilot fuel passages and two inner passages 151 and 152 are main fuel streams used for the fuel distributor 100. The road. Each channel 108 has a wall, for example, as shown as item 114, which separates the inner contour 141 of the channel 108 from the outer contour 140 of the conduit body 106. Adjacent channels 108 within the conduit body 106 are separated from each other by a separation barrier, for example as shown as item 116. In the exemplary embodiments shown in FIGS. 2 and 3, the main channels 151, 152 have diameters between about 0.060 inches and 0.150 inches, respectively, and the pilot channels 155, 157. Have diameters between about 0.040 inches and 0.150 inches, respectively. The wall 114 has a thickness between about 0.020 inches (about 0.051 cm) and 0.060 inches (about 0.152 cm). The separation wall 116 has a thickness between about 0.020 inches (about 0.051 cm) and 0.060 inches (about 0.152 cm).

Circular cross sections have usually been selected in the flow path based on manufacturing requirements. However, in certain cases, such as in fuel circuits exposed to thermal stress, it is advantageous to have a flow path 118 having a non-circular cross section. By properly contouring the inner portion of the flow path 108 and the outer contour 140 of the conduit body 106, stress concentration in the flow path 108 can be reduced. The flow path 108 may be circular (see FIG. 3) or elliptical (see FIG. 5). A circular passage would be shorter in length but wider in width. An elliptical passage would be narrower but longer in length. The narrower width provides more flexibility in the supply portion of the conduit 105, facilitating the reduction of thermal stress in the conduit body 106. FIG. 4 is an isometric view of a fuel distributor with conduit 105 according to an alternative exemplary embodiment of the invention, where channel 118 has a non-circular cross-sectional shape 121. FIG. 5 shows a cross-sectional view on the horizontal axis of the exemplary conduit 105 shown in FIG. The inner contour 141 of each flow path 118 can be selected to be circular, non-circular, or the proper combination of circular and non-circular. FIG. 5 shows an exemplary embodiment of a conduit 105 having one channel with a circular contour and three channels 118 with a non-circular contour 141. Each channel 118 has a wall 114 that separates its inner contour 141 from the outer contour 140 of the conduit body 106. The flow paths 118 adjacent to each other in the conduit body 106 are separated from each other by the separation wall 116. In the exemplary embodiment shown in FIG. 5, the non-circular flow path 118 is approximately 0.004 square inches (approximately 0.026 cm).²) And 0.018 square inches (about 0.116 cm)²), The circular pilot channel has a cross-sectional area of about 0.005 square inches (about 0.0323 cm).²) Has a cross-sectional area. The wall 114 has a thickness between about 0.020 inches (about 0.051 cm) and 0.060 inches (about 0.152 cm). The separation wall 116 has a thickness between about 0.020 inches (about 0.051 cm) and 0.060 inches (about 0.152 cm).

In the exemplary embodiment of the conduit 105 shown in FIGS. 2-5, the cross-sectional shapes 120, 121 of the flow path 108 remain substantially constant from the inlet end 111 to the outlet end 112 of the conduit 105. Similarly, the cross-sectional area of each flow path 108 may be substantially constant from the inlet end 111 to the outlet end 112 of the conduit 105. Alternatively, the cross-sectional area of the flow path 108 is preferably substantially uniform from the inlet end 111 to the outlet end 112 of the conduit 105 so as to achieve proper flow characteristics within the distributor tip 190 of the fuel nozzle. May change to. For example, it is possible to accelerate the fluid in several channels 108 within the conduit 105 by reducing the flow range, preferably substantially uniformly, between the inlet end 111 and the outlet end 112. is there.

In some applications, it is advantageous to vary the medial contour 141 and cross-sectional area of the flow path 108 of the conduit 105 between the inlet end 111 and the outlet end 112. 6-9 show an exemplary embodiment of a conduit 105 having four flow paths 108, having a first cross-sectional shape 131 near the inlet end 111 and a second cross-sectional shape 132 near the exit end 112. The cross-sectional shape 141 varies substantially uniformly between the first cross-sectional shape 131 near the inlet end 111 and the second cross-sectional shape 132 near the exit end 112. 7-9 show a cross-section of the conduit 105 near the inlet end 111, at the outlet end 112, and at an intermediate position between the inlet end 111 and the outlet end 112. As shown in FIGS. 7 to 9, in the first cross-sectional shape 131, each of the four passages 108 is circular. In the second cross-sectional shape 132 near the exit end 112, three of the passages are non-circular and the fourth passage (pilot passage 153) remains circular. FIG. 8 shows the cross section at the intermediate position and shows the change from the circular cross section to the non-circular cross section for the three flow paths 118.

In addition to varying the cross-sectional shapes 131, 132, it may be advantageous to vary the thickness of the walls 114 and separation walls 116 of the conduit 105 to reduce thermal stress and weight. For example, the conduit 105 is thinner near the outlet end 112 located near the distributor tip 190, from a thicker portion from the valve brazing area near the inlet end 111 to reduce the thermal stress of the conduit 105. It may change to a part. The wall thickness 114 of the fuel passage 108 may be kept substantially constant in a particular cross section in order to reduce weight as shown in FIG. Alternatively, in a particular cross section, the outer contour 140 of the conduit 106 and the wall thickness 114 of the flow path 108 so as to obtain a flat outer surface between the right and left ends of the flow path, as shown in FIG. You may shape the contour. Based on the thermal stress profile at the cross-sectional position, it may be advantageous to have a combination of the above means at different cross-sectional positions of the conduit 105. The cross section and outer contour 140 of the conduit 105 may be molded to generally conform to the shape of the passage in the conduit body 106 (see FIGS. 7-9), or they have a smooth outer surface (see FIGS. 3 and 5). It may be molded to have. In the fuel nozzle application of conduit 105, the fuel flowing through the pilot supply conduit cools the conduit body 106 and the fluid passages located within the conduit body, as described below, to help reduce thermal stress1. It is possible to locate one or more pilot supply conduits.

FIG. 10 is a partial cross-sectional isometric view of an exemplary single vessel 105 used to transport liquid fuel in a fuel nozzle. In an exemplary embodiment, the single conduit 105 includes a flow path 108 located within the conduit body 106 that acts as a main fuel passage into the fuel nozzle and a pilot fuel passage 153 extending within the conduit body 106. .. Fuel from the pilot fuel passage 153 is guided into the fuel nozzle by the pilot supply tube 154 and exits through the pilot fuel outlet 162. For some single vessels 105, it is advantageous to have a flow path 108 that branches into two or more sub-passages 109, 110, for example, as shown in FIG. As shown in FIG. 10 for applying the single conduit 105 to the fuel nozzle, the flow path 108 branches into a first main passage 151 and a second main passage 152. The liquid fuel is supplied into the nozzle through the main passage inlet 126 and enters the flow path 108. The fuel stream then branches into two streams, one through the first main passage 151 and the other through the second main passage 152 and then into the distributor tip 190. As shown in FIG. 10, the main fuel passage 108, the sub passages 151, 152, and the pilot fuel passage 153 are located between the inlet end 111 and the outlet end 112, generally at the conduit body 106 in the longitudinal direction 101. Extends along the axis.

An exemplary fuel distributor 100, which has a conduit 105 as described herein and is used in a gas turbine engine fuel nozzle, is shown in FIGS. 11-13. In an exemplary embodiment, the single vessel 105 is located within the stem 102, which has a flange 160 for mounting on the gas turbine engine 10. The single conduit 105 is located within the stem 102 so that there is a gap 107 between the inside of the stem and the conduit body 106 of the single conduit 105. The gap 107 insulates the single conduit 105 from heat and other adverse environmental conditions surrounding the fuel nozzles of the gas turbine engine. Additional cooling of the single vessel 105 is achieved by circulating air in the gap 107. The single conduit 105 is connected to the stem 102 using conventional connecting means such as brazing. Alternatively, the single conduit 105 and stem 102 may be manufactured by a rapid manufacturing method, such as, for example, direct laser metal sintering as described herein. In an exemplary embodiment, the fuel distributor tip 190 has a main fuel passage (first main passage 151 and second main passage 152) and a pilot fuel passage 153 flowing with the fuel distributor 300, for example, as shown in FIG. It extends from the single conduit 105 and the stem 102 so that they communicate and connect. Specifically, the main fuel passages 151, 152 are flow-tethered and coupled to a main fuel circuit defined within the fuel distributor 300. Similarly, the primary pilot passage 155 and the secondary pilot passage 157 are inwardly radially located within the fuel nozzle with the corresponding pilot injectors (see, eg, items 163 and 563 shown in FIG. 15). It is connected through the flow. Conduit 105 is described herein as a single conduit (ie, having a single structure), but use conduit 105 with other suitable manufacturing structures using methods known in the art. Will be apparent to those skilled in the art.

An isometric view of an exemplary fuel nozzle with Distributor Tip 190 and Distributor 300 is shown in FIG. FIG. 15 is an axial cross-sectional view of an exemplary distributor tip 190 of the exemplary fuel nozzle shown in FIG. An exemplary Distributor Tip 190 provides Distributor 300, as described above, to receive fuel flow from the supply conduit 105 and distribute fuel to various locations on the fuel nozzle, such as the main fuel passage and pilot fuel passage, as described below. Including. FIGS. 15-20 show exemplary embodiments of the invention having two main channels 304, 305 and two pilot channels 402, 502, which distribute fuel at the fuel nozzle tip assembly 68. 21-23 show another exemplary embodiment of the invention having two main channels 604, 603 and a single pilot channel 602.

The exemplary Distributor 300 shown in FIGS. 15-20 includes the Distributor Body 301, which includes the main and pilot channels described herein. The main channels 302, 303 of the Distributor 300 communicate with the corresponding main channels of the supply conduit 105 (eg, items 151, 152 in FIG. 3). The exemplary main fuel passages shown and described herein are inlets that transport fuel flow from the supply conduit 105 to two arched portions 304, 305 located circumferentially around the distributor shaft 11, respectively. Includes 307.

Referring to FIG. 16, at the viewing angle shown therein, the main flow path includes a left axis portion (shown as item 302) and a right axis portion (shown as item 303). The flow in the left shaft portion 302 and the right shaft portion 303 is generally axial with respect to the distributor shaft 11. The flow rate from the left shaft portion 302 of the main flow path enters the left circumferential portion 304. The circumference 304 of the left main flow path has an arch shape that is generally oriented in the circumferential direction around the distributor shaft 11. Similarly, the flow rate from the right shaft portion 303 of the main flow path enters the right circumferential portion 305. The right main flow path circumferential portion 305 has an arch shape that is generally oriented in the circumferential direction around the distributor shaft 11. The left circumference 304 and the right circumference 305 of the main flow path are generally located at the same axial position (see FIG. 15) and are separated by a wall 306 that prevents the flows from the two circumferential paths from mixing. .. The fluid flow direction of the main flow path is shown in FIG. 16 as item 317 in the left passages 302 and 304 and as item 318 in the right passages 303 and 305. The fuel flows clockwise in the right circumferential portion 305 of the main passage and counterclockwise in the left circumferential portion 304 of the main passage. Although the two axial passages 302, 303 and the corresponding circumferential passages 304, 305 are shown in the embodiments described herein, it is possible for the channels to have other arrangements, the single distributor 300. It will be appreciated by those skilled in the art that other orientations are within the scope of the present invention.

As shown in FIG. 16, the fuel flow from the main flow paths 304 and 305 is located in the distributor ring main body 301 and is circumferentially connected from the distributor 300 by a plurality of mainstream outlet passages 308 arranged around the distributor shaft 11 in the circumferential direction. Guided outward in the direction. In the exemplary embodiments shown in FIGS. 15-25, each mainstream outlet passage 308 is located inside the fuel post 310. The fuel post 310 is formed as part of the distributoring body 301. Each outlet passage 308 flows and communicates with the main passages 304 and 305. Pressurized fuel from the main passages 304 and 305 enters the outlet passage 308 and is ejected from the distributor 300 as fuel injection 309 (see FIG. 16). In some embodiments of the invention described herein, the main channels 304, 305 are uniformly varied in the circumferential direction in the cross-sectional areas of the passages 304, 305 (marked "P" in FIG. 16). It is possible to do so. The change in the cross-sectional area "P" is the main flow path 304, 305 as a fuel flow in the passages 304, 305 into a plurality of outlet passages 308 arranged circumferentially around the distributor axis of the distributor ring body 301. It is sized using known methods to maintain a constant pressure within.

As mentioned above, fuel nozzles, such as fuel nozzles used in gas turbine engines, are exposed to high temperatures. Such exposure to high temperatures may result in fuel coking and blockage in fuel passages, such as the outlet passage 308, located in the distributoring body 301, for example. One way to mitigate fuel coking and / or blockage in Distributor 300 is to use heat shields to protect passage 308 from adverse thermal environments. In an exemplary embodiment of the invention shown in FIGS. 16 and 24, the fuel post 310 is protected by a heat shield surrounding the fuel post 310. An exemplary embodiment shown in FIG. 24 includes a front heat shield 312 and a rear heat shield 314 surrounding a heat post 310. As shown in FIG. 16, the heat shield may also surround at least a portion of the main channels 304, 305 in the circumferential direction around the distributor shaft 11. The heat shields 314, 312 are manufactured so that there is an insulating gap 316 between the walls of the fuel passages (eg, labeled items 308, 304, 305 in FIGS. 16 and 24) and the heat shields 312, 314. Insulation clearance 316 provides the fuel passage with additional protection from adverse thermal environments. The heat shield can be made of any suitable material capable of withstanding high temperatures, such as cobalt-based alloys and nickel-based alloys commonly used in gas turbine engines. For example, in an exemplary embodiment of the invention, as shown in FIGS. 15-25, the distributor 300 is a distributor ring body 301, flow path 302, 303, 305, 306, fuel post 310, heat shield 312, 314, And the gap 316 has a single structure formed to have an integral structure. Methods for manufacturing such a standalone Distributor 300 are described herein below.

In another aspect of the invention, the standalone Distributor 300 is used to flow pilot fuel to cool the Distributor Body 301 and protect the flow path from the adverse thermal environment, eg, as Items 402, 502 in FIG. It has at least one flow path, such as. FIGS. 15-20 show exemplary embodiments of the invention having two pilot fuel cooling channels, referred to herein as primary pilot flow paths 402 and secondary pilot flow paths 502. Referring to FIG. 15, the fuel from the primary pilot flow path 402 exits the fuel nozzle via the primary pilot fuel injector 163, and the fuel from the secondary pilot fuel flow path 502 is the secondary pilot fuel. It exits the fuel nozzle via injector 563. The primary pilot flow path 402 of the Distributor 300 communicates with the corresponding pilot primary passage 155 of the supply conduit 105 (see, eg, FIG. 3). Similarly, the secondary pilot aisle 502 of the Distributor 300 flows through the corresponding pilot secondary aisle 157 of the supply conduit 105 (see, eg, FIG. 3).

Referring to FIG. 17, the primary pilot flow path 402 of the Distributoring Body 301 serves as a primary pilot fuel receiving position, for example, from the pilot primary passage 155 of the supply conduit 105. Includes entrance 401. The primary pilot flow path 402 further includes a primary pilot flow inflow path 403 and a circumferential portion 404 oriented circumferentially with respect to the distributor axis 11. In the exemplary embodiment shown in FIG. 17, the primary pilot flow inflow path is generally shown as having an axial orientation with respect to the distributor shaft 11. Other orientations may also be used for the primary pilot flow inflow path 403. The primary pilot fuel flow from the inflow path 403 enters the circumferential portion 404 of the primary flow path 402 and flows in the circumferential direction as indicated by the flow direction arrow shown as item 406 in FIG. The lower temperature pilot fuel stream of the primary pilot flow path 402 provides cooling to the distributor ring body 301 and the fuel flow path located within the distributor 300 in order to reduce the adverse effects of the high temperature exposure described above. .. Referring to FIG. 18, the primary pilot fuel flow from the circumferential flow path 404 (see item 406) enters the primary pilot flow outflow channel 405 located at Distributor 300. In the exemplary embodiment shown in FIG. 18, the primary pilot outflow channel 405 is generally shown as having an axial orientation with respect to the distributor axis 11. Other orientations may also be used for the primary pilot flow outflow channel 405. In the exemplary embodiment shown in FIG. 18, the distributor 300 includes a primary pilot supply tube section 154 that flows and communicates with the outflow channel 405, with the primary pilot fuel radially inward in the direction of the distributor shaft 11 and. Oriented in the direction of the primary fuel outlet 162. The first pilot fuel exits the distributoring body 301 via the primary pilot fuel outlet 162 and is ejected from the fuel nozzle by the primary pilot fuel injector 163. In the exemplary embodiment shown in FIG. 15, 1 The circumferential portion 404 of the pilot flow path 402 is located at the distributor ring main body 301 at an axially forward position from the main flow paths 304 and 305. In an alternative embodiment, the circumferential portion 404 of the first pilot flow path 402 is located axially rearward from the main flow paths 304, 305.

With reference to FIGS. 15 and 19, exemplary embodiments of the invention include a secondary pilot flow path 502. The secondary pilot fuel flows through the secondary pilot flow path 502, as indicated by arrow 506 in the flow direction in FIG. The secondary pilot flow path 502 located in the distributor ring body 301 serves as a receiving position for the secondary pilot fuel, such as from the pilot secondary passage 157 of the supply conduit 105. including. The secondary pilot flow path 502 further includes a secondary pilot flow inflow path 503 and a circumferential portion 504 oriented in the circumferential direction with respect to the distributor axis 11. In the exemplary embodiment shown in FIG. 19, the secondary pilot flow inflow path 503 is generally shown to have an axial orientation with respect to the distributor shaft 11. Other orientations may also be used for the secondary pilot flow inflow path 503. The secondary pilot fuel flow from the inflow path 503 enters the circumferential portion 504 of the secondary flow path 502 and flows in the circumferential direction as indicated by the flow direction arrow shown as item 506 in FIG. The lower temperature pilot fuel stream of the secondary pilot flow path 502 provides cooling to the distributor ring body 301 and the fuel flow path located within the distributor 300 in order to reduce the adverse effects of the high temperature exposure described above. .. Referring to FIG. 19, the secondary pilot fuel flow from the circumferential flow path 504 (see item 506) enters the secondary pilot flow outflow channel 505 located at Distributor 300. In the exemplary embodiment shown in FIG. 19, the secondary pilot outflow channel 505 is generally shown to have an axial orientation with respect to the distributor axis 11. Other orientations may also be used for the secondary pilot flow outflow channel 505. In the exemplary embodiment shown in FIGS. 15-20, the circumferential portion 504 of the secondary pilot flow path 502 is located at the distributor ring body 301 axially rearward from the main flow paths 304, 305. In an alternative embodiment, the circumferential portion 504 of the secondary pilot flow path 502 is the main flow path 3 It may be located axially forward from 04 and 305. With reference to FIGS. 17 and 19, the circumferential primary pilot fuel flow direction 406 is counterclockwise and the circumferential secondary pilot fuel flow direction 506 is clockwise. In an alternative embodiment of the invention, the flow directions of the primary and secondary fuel paths may have different orientations or the same orientation.

In one aspect of the invention, the primary pilot flow path 404 and the secondary pilot flow path 504 of the Distributor Ring 301 are protected by insulating gaps, such as item 316 in FIGS. 15, 17 and 19. Similarly, insulation clearances, such as item 516 in FIGS. 15 and 18, are provided around at least a portion of the pilot injector. These insulating gaps provide the fuel flow path with at least some protection from the high temperatures experienced by the distributoring body 301 and help reduce the incidence of coking and / or blockage in the flow path and injectors. In the exemplary embodiment shown, the insulation gap has a width between about 0.015 inches (about 0.038 cm) and 0.025 inches (about 0.064 cm). In another aspect of the invention, the insulating gaps of items 316, 516 and 616 of FIGS. 15-24 are placed within the distributoring body 301 having a single structure using the methods described herein below. It can be manufactured integrally.

An exemplary embodiment of the invention with a single pilot flow path 602 for a fuel nozzle with a single pilot injector 663 is shown in FIGS. 21-24. Exemplary embodiments of the Fuel Distributor 100 are similar to those previously described herein, including fuel posts 610, main fuel outlets 661, front heat shields 612, and rear heat shields 614 in main channels 603, 604. , And a distributor body 601 with an insulating gap 616. The front and rear heat shields may be coupled to the integrally molded heat shield 611 (see FIG. 23). The pilot injector 663 receives the pilot fuel flow from the pilot supply tube 654 (see Figure 22). The pilot fuel flow path has a circumference as previously described herein for flowing pilot fuel that cools the distributoring body 601. The exemplary embodiments shown in FIGS. 21-24 further include an insulating gap 616 that protects the flow path from an adverse thermal environment, eg, as shown in FIG. In one aspect of the invention, the exemplary embodiment of Distributor 300 shown in FIG. 21 has a simple substance structure using the methods described herein below.

In another aspect of the invention, the Distributor 300 has an annular ring 670 (see FIGS. 15, 21, 23) located at the front end of the Distributor Ring Body 301 and located coaxially with it. The annular ring 670 includes an annular ring wall 672 and extends axially forward from the distributor ring body 301. In one aspect of the invention, the annular ring 670 has a slot 674 extending axially and circumferentially. The shaft slot 674 engages with other parts of the fuel nozzle during assembly and provides a means to ensure the correct orientation of the Distributor 300 during assembly within the fuel nozzle. In another aspect of the invention, collision cooling holes 680 extending within the annular ring wall 672 are provided. During fuel nozzle operation, cooling air (not shown) passes inwardly in the radial direction through the cooling holes 680 and collides with adjacent components of the fuel nozzle, providing cooling to these components. In the exemplary embodiment shown in FIG. 25, the annular ring wall has a thickness between 0.025 inches (about 0.064 cm) and 0.035 inches (about 0.089 cm). Two rows of cooling holes 680 are used, with each row having 40 to 60 holes, each with a diameter between about 0.025 inches (about 0.064 cm) and 0.040 inches (about 0.102 cm). In one aspect of the invention, the exemplary embodiment of Distributor 300 shown in FIG. 25 has a simple substance structure using the methods described herein below. In an exemplary embodiment, the single distributor 300 shown in FIG. 25 may have cooling holes 680 and slots 674 formed between the single structures.

The exemplary embodiments of the Single Distributor 300 shown in FIGS. 15-20 and the alternative embodiments of the Single Distributor 300 shown in FIGS. 21-25 are Direct Metal Laser Sintering (DMLS), Laser Net Shape Manufacturing (LNSM), It can be manufactured using rapid manufacturing processes, such as electron beam sintering and other known manufacturing processes. DMLS is the preferred method for producing the single conduit 105, single distributor 300 and single fuel distributor 100 described herein.

FIG. 26 is a flow chart illustrating an exemplary embodiment of a method 200 for manufacturing the single conduit 105, the single distributor 300, and the single fuel distributor 100 described herein. Method 200 includes the step of making a single distributor 300 (shown in FIGS. 15-25) using direct metal laser sintering (DMLS). DMLS is a known manufacturing process that uses 3D information about a component, eg, a 3D computer model, to make a metal component. The 3D information is transformed into multiple slices, each slice defining a cross section of a component of a slice of a given height. The components are then "built up" slice by slice or layer by layer until they are complete. Each layer of the component is formed by melting the metal powder using a laser.

Therefore, method 200 includes step 205 to determine the 3D information of the single distributor 300 and step 210 to transform the 3D information into multiple slices where each slice defines the cross-sectional layer of the single distributor 300. The single distributor 300 is then made using DMLS, or more specifically, each layer is formed one after the other in step 215 by melting the metal powder using laser energy. Each layer has dimensions between about 0.0005 inches and about 0.001 inches. The standalone distributor 300 may be manufactured using any suitable laser sintering machine. Examples of suitable laser sintering machines are, but are not limited to, EOSINT.RTM.M270DMLS machines, PHENIX PM250 machines, and / or EOSINT.RTM.M available from EOS of North America, Inc. in Novi, Michigan. 250 Xtended Includes DMLS machine. The metal powder used to make the Elemental Distributor 300 is preferably a powder containing cobalt chromium, but may be any other suitable metal powder, such as, but not limited to, HS188 and INCO625. The metal powder can have a particle size between about 10 microns and 74 microns, but preferably between about 15 microns and about 30 microns.

Although it is stated herein that DMLS is used as the preferred method for manufacturing the Single Distributor 300, any other suitable rapid manufacturing method using layer-by-layer construction or additional fabrication may also be used. , Will be understood by those skilled in the art. These alternative rapid manufacturing methods are, but are not limited to, selective laser sintering (SLS), 3D printing with inkjet and racer jets, stereolithography (SLS), direct selective laser sintering (DSLS), electronic. Includes beam sintering (EBS), electron beam melting (EBM), laser technology net-shaping method (LENS), laser net-shaping manufacturing (LNSM) and direct metal deposition (DMD).

The single distributor 300 for the fuel distributor 100 of the turbine engine (see Figures 11-25) contains fewer components and fittings than known fuel nozzles. In particular, the Single Distributor 300 may be one or more, as shown, for example, as Items 302, 304, 402, 403, 404, 405, 503, 505 and 602 in FIGS. 15-23 included herein. Since the integrated distributoring body 301 having the flow path of is used, less components are required. As a result, the described fuel distributor 100 provides a lighter, less costly alternative to known fuel distributors. In addition, the described standalone structure for Distributor 300 or Fuel Distributor 100 has less chance of leakage or failure compared to known distributors and is easier to repair.

As used herein, steps listed in the singular or without numerals should be understood not to exclude multiple said elements or steps unless it is explicitly stated to exclude more than one. Is. When introducing the elements / components / steps of the Elemental Venturi 500, 600 described and / or exemplified herein, the absence of numerals and articles such as "above" may be one or more elements / components. Intended to mean that there is / etc. The terms "comprising", "including" and "having" are comprehensive and mean that there may be additional elements / components / etc. in addition to the listed elements / components / etc. Intended to. Furthermore, reference to "one embodiment" of the present invention is not intended to be construed as excluding the existence of additional embodiments that also incorporate the listed features.

The methods described herein and articles such as conduit 105, distributor 300, and fuel distributor 100, which are described in the context of supplying liquid fuel to the turbine engine, are described herein. It should be understood that the Distributor 300, and the Fuel Distributor 100 and the methods of their manufacture are not limited to fuel distributors or turbine engines. The components of conduit 105, distributor 300 or fuel distributor 100 depicted in the drawings contained herein are not limited to the particular embodiments described herein, but rather they are described herein. It can be used individually, independently of other components.

This document includes the best forms and uses examples to disclose the invention and to allow those skilled in the art to manufacture and use the invention. The patentable scope of the invention is defined by the claims and may include other examples noticed by those skilled in the art. Such other examples are such that the example has structural elements that do not differ from the wording of the claims, or that the example differs only slightly from the wording of the claims. If it contains an accompanying equivalent structural element, it is intended to be within the scope of the claims.

10 turbine engine 11 Distributor axis 12 Axial centerline axis 16 fan section 18 outer casing 20 Ring entrance 22 Booster 24 Multi-stage axial flow compressor 26 Combustor 28 turbine 30 drive shaft 32 turbine 34 drive shaft 36 Exhaust nozzle 38 Axial fan rotor 40 annular fan casing 42 Guide vane 44 fan blade 46 downstream section 48 conduit 50 air flow 52 entrance 54 Air flow 56 Air flow 58 air flow 60 Combustion products / combustion gas 62 Combustion chamber 64 entrance 66 Exit 68 Nozzle tip assembly 69 exit 72 turbine nozzle 74 Nozzle vane 100 distributors 101 vertical 102 stem 105 conduit 106 Vessel body 107 Gap 108 Channel 109 Sub passage 110 sub-passage 111 Entrance end 112 Exit end 114 wall 116 Separation barrier 118 Channel 120 cross-sectional shape 121 Cross-sectional shape 126 Main passage entrance 131 Cross-sectional shape 132 Cross-sectional shape 140 outer contour 141 Inner contour 151 Main fuel passage 152 Main fuel passage 153 Pilot fuel passage 154 Pilot supply tube 155 passage 157 passage 160 flange 161 Main fuel outlet 162 Pilot fuel outlet 163 Pilot fuel injector 190 Fuel Distributor Tip 300 distributor 301 Distributor ring body 302 Main flow path 303 Main flow path 304 Main flow path 305 Main flow path 306 wall 307 entrance 308 Mainstream exit passage 309 Fuel injection 310 fuel post 312 heat shield 314 heat shield 316 Insulation gap 317 Fluid flow direction 318 Fluid flow direction 401 Pilot entrance 402 Pilot flow path 403 Inflow route 404 pilot flow path 405 Outflow channel 406 Pilot fuel flow direction 502 Pilot flow path 503 Inflow route 504 Pilot flow path 505 pilot outflow channel 506 Pilot fuel flow direction 507 Pilot entrance 516 Insulation gap 563 Pilot fuel injector 601 Distributor ring body 602 Pilot flow path 603 Main flow path 604 Main flow path 610 fuel post 611 heat shield 612 Front heat shield 614 Rear heat shield 616 Insulation gap 654 Pilot supply tube 661 Main fuel outlet 663 Pilot injector 670 Ring ring 672 Ring ring wall 674 slots 680 Cooling holes