A multi-channel particle separator includes a plurality of vanes. Each vane is spaced apart from at least one other adjacent vane to define a flow channel, and includes a leading edge, a trailing edge, a first side wall, a second sidewall, and a splitter. The first side wall extends between the leading edge and the trailing edge. The second side wall is spaced apart from the first side wall and extends from the leading edge toward the trailing edge. The splitter may be rotationally coupled to the trailing edge and extend toward the leading edge. The splitter is spaced apart from the first side wall to define a scavenge volume and is rotatable between an extended position and a retracted position. The vanes may also or instead be coupled to a ring-shaped structure.

TECHNICAL FIELD

The present invention generally relates to inlet particle separator systems for gas turbine engines, and more particularly relates to a multi-channel particle separator (MCPS) for aircraft that include one or more gas turbine engines.

BACKGROUND

In many aircraft, the main propulsion engines not only provide propulsion for the aircraft, but may also be used to drive various other rotating components such as, for example, generators, compressors, and pumps, to thereby supply electrical and/or pneumatic power. However, when an aircraft is on the ground, its main engines may not be operating. Moreover, in some instances the main propulsion engines may not be capable of supplying the power needed for propulsion as well as the power to drive these other rotating components. Thus, many aircraft include an auxiliary power unit (APU) to supplement the main propulsion engines in providing electrical and/or pneumatic power. An APU may also be used to start the propulsion engines.

Many APU-equipped aircraft are operated in environments that have a high concentration of fine dust particles (e.g., <30 μm) suspended in the air. These fine dust particles, when ingested by the APU, can adversely impact the APU. For example, the fine dust particles can plug the holes in effusion cooled combustors, and can plug and corrode the high temperature turbine passages and hardware. To alleviate the adverse impact of dust particles, many aircraft include an inlet particle separator system (IPS).

Most IPSs are designed to separate out relatively large particles (e.g., 100 μm<1000 μm) but are less efficient at separating out fine particles. This is because these systems typically rely on particle inertia to move the particles into a separate collector and scavenge system. Fine particles, with relatively lower inertia, are much more inclined to follow the inlet airflow into the gas turbine engine, resulting in low separation efficiencies. Thus, many aircraft additionally include one or more systems to remove these fine particles. These additional systems include barrier filters (self-cleaning and non-self-cleaning), vortex panels, and multi-channel particle separator (MCPS) systems.

Although the three particle separator systems just mentioned do excel at removing fine particles from APU inlet airflow, they all exhibit certain drawbacks. In particular, each is designed to be relatively large in size in order to minimize pressure losses. This size requirement negates the ability to mount these systems inside the already existing APU inlet duct system.

Hence, there is a need for a particle separator system that can remove fine dust particles from APU inlet airflow, exhibit minimal pressure losses, and be incorporated into the APU air inlet system. The present invention addresses at least this need.

BRIEF SUMMARY

In one embodiment, a multi-channel particle separator includes a plurality of vanes. Each vane is spaced apart from at least one other adjacent vane to define a flow channel. Each vane includes a leading edge, a trailing edge, a first side wall, a second sidewall, and a splitter. The first side wall extends between the leading edge and the trailing edge. The second side wall is spaced apart from the first side wall and extends from the leading edge toward the trailing edge. The splitter is rotationally coupled to the trailing edge and extends toward the leading edge. The splitter is spaced apart from the first side wall to define a scavenge volume and is rotatable between an extended position and a retracted position. In the extended position, the splitter is spaced apart from the second side wall to place the scavenge volume in fluid communication with the flow channel. In the retracted position, the splitter engages the second side wall to fluidly isolate the scavenge volume from the flow channel.

In another embodiment, a multi-channel particle separator includes a generally ring-shaped support structure and a plurality of vanes. The support structure has a particulate collection chamber formed therein, and is symmetrically disposed about a central axis. The vanes are coupled to the support structure and are symmetrically disposed around the central axis. Each vane is spaced apart from two other adjacent vanes to define a plurality of flow channels. Each vane includes a leading edge, a trailing edge, a first side wall, a second side wall, and a splitter. The leading edge is disposed parallel to the central axis. The first side wall extends between the leading edge and the trailing edge. The second side wall is spaced apart from the first side wall, and extends from the leading edge toward the trailing edge. The splitter is coupled to the trailing edge and extends toward the leading edge. The splitter is spaced apart from the first side wall to define a scavenge volume that is in fluid communication with the particulate chamber.

In yet another embodiment, a multi-channel particle separator includes a generally ring-shaped support structure, a plurality of particle collectors, and a plurality of vane sets. The ring-shaped structure is symmetrically disposed about a central axis, and has a plurality of evenly spaced-apart openings formed therein. The particle collectors are coupled to and extend perpendicularly from the support structure. Each particle collector has an inner surface that defines a particulate collection chamber that is in fluid communication with a different one of the openings. Each vane set includes a plurality of vanes that are coupled between two particle collectors and are spaced apart from at least one other adjacent vane to define a plurality of flow channels. Each vane includes a leading edge, a trailing edge, a first side wall, a second sidewall, and a splitter. The leading edge is disposed perpendicular to the central axis. The first side wall extends between the leading edge and the trailing edge. The second side wall is spaced apart from the first side wall, and extends from the leading edge toward the trailing edge. The splitter is coupled to the trailing edge and extends toward the leading edge. The splitter is spaced apart from the first side wall to define a scavenge volume that is in fluid communication with the particulate chamber.

Furthermore, other desirable features and characteristics of the multi-channel particle separator will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the preceding background.

DETAILED DESCRIPTION

Turning now toFIG. 1, a functional block diagram of an exemplary gas turbine engine100is depicted. The depicted engine100is a single-spool turbo-shaft gas turbine propulsion engine, and includes a compressor section102, a combustion section104, a turbine section106, and an exhaust section108. The compressor section102, which may include one or more compressors112, draws air into the engine100and compresses the air to raise its pressure. In the depicted embodiment, only a single compressor112is shown, though it will be appreciated that one or more additional compressors could be used.

No matter the particular number of compressors112that are included in the compressor section102, the compressed air is directed into the combustion section104. In the combustion section104, which includes a combustor assembly114, the compressed air is mixed with fuel supplied from a non-illustrated fuel source. The fuel and air mixture is combusted, and the high energy combusted air mixture is then directed into the turbine section106.

The turbine section106includes one or more turbines. In the depicted embodiment, the turbine section106includes two turbines, a high pressure turbine116and a low power turbine118. However, it will be appreciated that the engine100could be configured with more or less than this number of turbines. No matter the particular number, the combusted air mixture from the combustion section104expands through each turbine116,118, causing it to rotate a power shaft122. The combusted air mixture is then exhausted via the exhaust section108. The power shaft122may be used to drive various devices within the engine or vehicle. For example, in the context of a helicopter, the power shaft may be used to drive one or more rotors.

AsFIG. 1further depicts, the gas turbine engine100also includes an inlet particle separator system150. The depicted inlet particle separator system150includes a multi-channel particle separator MCPS152, an actuator154, a control156, and a sensor158. The MCPS is152is coupled to, and is disposed upstream of, the compressor section102. The air that the compressor section102draws into the engine100first enters the MCPS system150. The MCPS152, embodiments of which will be described in more detail further below, is configured to selectively separate at least a portion of any particulate that is suspended in the air that is drawn into the engine100. The separated particulate, along with a portion of the air that is drawn into the engine100, may be drawn into, for example, a scavenge scroll162via, for example, an air pump164(e.g., a blower or the like). The configuration of the MCPS152that allows the selective separation functionality will now be described.

Turning toFIGS. 2 and 3, simplified representations of a portion of the MCPS152are depicted. The MCPS152includes a plurality of vanes202(202-1,202-2. . . ). Depending upon the specific configuration of the MCPS152, variations of which are described further below, each vane202is spaced apart from at least one other adjacent vane202to define a flow channel204. Each of the vanes202includes a leading edge206, a trailing edge208, a first side wall212, a second side wall214, and a splitter216. Preferably, both the leading edge206and the trailing edge208are substantially rounded, though other shapes and configurations could be used. Regardless of the specific shape and configuration, it is seen that the first side wall212extends between the leading edge206and the trailing edge208, and the second side wall214is spaced apart from the first side wall212and extends from leading edge206toward the trailing edge208.

The splitter216is rotationally coupled to the trailing edge208via, for example, a hinge-type connection209, and extends toward the leading edge206. The splitter216is also spaced apart from the first side wall206to define a scavenge volume218. The splitter216, because it is rotationally coupled to the trailing edge208, is rotatable between two positions—an extended position and a retracted position. In the extended position, which is the position depicted inFIG. 2, the splitter216is spaced apart from the second side wall214to place the scavenge volume218in fluid communication with the flow channel204. In the retracted position, which is the position depicted inFIG. 3, the splitter216engages the second side wall214to fluidly isolate the scavenge volume218from the flow channel204. AsFIGS. 2 and 3depict, and as will now be described, the splitter is moved between the extended and retracted position via the actuator154, which is coupled to each splitter216.

Returning now toFIG. 1, it is seen that only a single actuator154is depicted. It should be noted that this is merely exemplary of one embodiment and that in some embodiments two or more actuators154could be used to move the splitters216. Regardless of the number of actuators that are used, the depicted actuator154is coupled to receive actuator control signals from the control156. The actuator154is configured, in response to the actuator control signals, to move each splitter216to either the extended position or the retracted position. It will be appreciated that the actuator154may be implemented using any one of numerous actuators known in the art.

The control156is in operable communication with both the actuator154and the sensor158. The control156receives a sensor signal from the sensor158and is configured, in response to the sensor signal, to supply the actuator control signals to the actuator154. The sensor158, which may be variously implemented, is configured to sense at least one parameter representative of a need for particle separation, and to supply a sensor signal that is representative thereof to the control156.

It will be appreciated that the parameter (or parameters) that the sensor158is configured to sense, and the type of sensor, may vary. For example, the sensor158may be one or more of a particle sensor or, if the engine100is installed in an aircraft, an altitude sensor or a weight-on-wheels sensor, just to name a few. If the sensor158is a particle sensor, when the sensor signal supplied to the control156indicates, for example, that particulate concentration in the inlet air is above a threshold concentration, the control156will command the actuator154to move the splitters216to the extended positions. When the sensor signal supplied to the control156indicates that particulate concentration in the inlet air is below the threshold concentration, the control156will command the actuator154to move the splitters216to the retracted positions, and thereby reduce pressure loss across the MCPS152. If the sensor158is configured to sense altitude or weight-on-wheels, the control156may be configured to command the actuator154to move the splitters216to the extended position at or below a threshold altitude or when the aircraft is on the ground, and to move the splitters216to the retracted position when the aircraft is at or above a threshold altitude or when the aircraft is not on the ground.

The MCPS152, as noted above, may be variously configured and implemented. Two alternative configurations are depicted inFIGS. 4-9and will now be described, beginning with the embodiment depicted inFIGS. 4 and 5.

In the embodiment depicted inFIGS. 4 and 5, the vanes202are coupled between two support structures. In particular, one end402of each vane202is coupled to a first support structure404, and the other end406of each vane202is coupled to a second support structure408. It will be appreciated that the vanes202, in some embodiments, could be coupled to only the first support structure404.

The first support structure404, as shown most clearly inFIG. 5, has a particulate collection chamber502formed therein. The particulate collection chamber502is in fluid communication with the scavenge volume218of each vane202. In addition, the scavenge scroll162and air pump164(seeFIG. 1) are preferably disposed in fluid communication with the particulate collection chamber502. Thus, when the splitters216are in the extended position any particulate that is collected in the scavenge volumes208of the vanes202will be drawn into, and discharged from, the particulate collection chamber502.

It is additionally seen that the first and second (if included) support structures404,408are generally ring-shaped structures that are concentrically and symmetrically disposed about a central axis412. The vanes202are also symmetrically disposed around the central axis412, and the leading edge204of each vane202is disposed parallel to the central axis412.

With this configuration, as shown more clearly inFIG. 6, the MCPS152, when installed, is preferably disposed circumferentially around the rotational axis602of the engine100. As such, the central axis412is aligned with the rotational axis602. It will be appreciated that the depicted installation configuration is for an engine100that is configured as an auxiliary power unit (APU), and the MCPS152is installed in an APU inlet plenum604. It has been found that the orientation of the flow channels204provide an angular flow exit, which may impart some bulk swirl to the air entering the compressor section102. If needed, this bulk swirl can be eliminated by orienting the MCPS152as depicted inFIGS. 7 and 8.

In the embodiment depicted inFIGS. 7 and 8, the vanes202are grouped together into sets of vanes702(702-1,702-2,702-3. . .702-8). Although the depicted embodiment includes eight sets of vanes702, it will be appreciated that the MCPS152could be implemented with more or less than this number. Regardless of the number of sets702, it is additionally seen that the MCPS152further includes a plurality of particle collectors704and a support structure706.

Each particle collector704is coupled to two different sets of vanes702. More specifically, each particle collector704is coupled to one of the ends of each vane202in a set of vanes702, and to the other end of each vane202in another set of vanes702. AsFIG. 8depicts, each particle collector704has an inner surface802that defines a particulate collection chamber804. Each particulate collection chamber804is in fluid communication with the scavenge volume218of each vane202to which it is coupled.

The support structure706is coupled to each particle collector704, and has a plurality of openings712formed therein. Each of these openings712is aligned with a different one of the particulate collection chambers804. The support structure706, as with the embodiment depicted inFIGS. 4-6, is a generally ring-shaped structure that is symmetrically disposed about a central axis714, and the vanes202are disposed around this central axis714. However, unlike the embodiment depicted inFIGS. 4-6, the leading edge204of each vane202is disposed perpendicular, rather than parallel, to the central axis714.

The installation configuration of the MCPS152depicted inFIGS. 7 and 8and described above is depicted inFIG. 9. As with the embodiment depicted inFIGS. 4-6, the MCPS152of this embodiment is also preferably disposed circumferentially around the rotational axis902of the engine100so that the central axis714is aligned with the rotational axis902. The depicted installation configuration is again for an engine100that is configured as an auxiliary power unit (APU), and the MCPS152is installed in an APU inlet plenum904.

The MCPS152embodiments described herein may be variously shaped. This flexibility allows for the MCPS152to be used in various other applications. One alternative application, which is depicted inFIG. 10, is in front of an air/oil cooler (AOC)1002. The MCPS152will protect the AOC1002from particle plugging or damage. It will be appreciated that the arrangement of the vanes202could vary (cylindrical, linear, etc.), as needed or desired.

It will be appreciated that the MCPS152embodiments depicted inFIGS. 4-10may be implemented using non-movable splitters216. That is, the splitters216may be permanently disposed in the extended positions and not movable to the retracted position.