Angle-of-attack effects on counter-rotating propellers at take-off

Due to their potential for significant fuel consumption savings, Counter-Rotating Open Rotors (CRORs) are currently being considered as an alternative to high-bypass turbofans. When CRORs are mounted on an aircraft, several 'installation effects' arise which are not present when the engine is operated in isolation. This paper investigates how flow features arising from one such effect - The angle-of-attack of the engine centre-line relative to the oncoming flow - can influence the design of CROR engines. Three-dimensional full-annulus unsteady CFD simulations are used to predict the time-varying flow field experienced by each rotor and emphasis is put on the interaction of the frontrotor wake and tip vortex with the rear-rotor. A parametric study is presented that quantifies the rotorrotor interaction as a function of the angle-of-attack. It is shown that angle-of-attack operation significantly changes the flow field and the unsteady lift on both rotors. In particular, a frequency analysis shows that the unsteady lift exhibits sidebands around the rotor-rotor interaction frequencies. Further, a non-linear increase in the total rear-rotor tip unsteadiness is observed for moderate and high angles-of-attack. The results presented in this paper demonstrate that common techniques used to mitigate CROR noise, such as modifying the rotor-rotor axial spacing and rear-rotor crop, can not be applied correctly unless angle-of-attack effects are taken into account. Copyright © 2012 by ASME.

An investigation into numerical analysis alternatives for predicting reingestion in turbine disc rim cavities

Reliable means of predicting ingestion in cavities adjacent to the main gas path are increasingly being sought by engineers involved in the design of gas turbines. In this paper, analysis is to be presented that results from an extended research programme, MAGPI, sponsored by the EU and several leading gas turbine manufactures and universities. Extensive use is made of CFD modelling techniques to understand the aerodynamic behaviour of a turbine stator well cavity, focusing on the interaction of cooling air supply with the main annulus gas. The objective of the study has been to benchmark a number of CFD codes and numerical techniques covering RANS and URANS calculations with different turbulence models in order to assess the suitability of the standard settings used in the industry for calculating the mechanics of the flow travelling between cavities in a turbine through the main gas path. The modelling methods employed have been compared making use of experimental data gathered from a dedicated two-stage turbine rig, running at engine representative conditions. Extensive measurements are available for a range of flow conditions and alternative cooling arrangements. The limitations of the numerical methods in calculating the interaction of the cooling flow egress and the main stream gas, and subsequent ingestion into downstream cavities in the engine (i.e. re-ingestion), have been exposed. This has been done without losing sight of the validation of the CFD for its use for predicting heat transfer, which was the main objective of the partners of the MAGPI Work- Package 1 consortium. Copyright © 2012 by ASME.

An investigation of higher-order multi-objective optimisation for 3D aerodynamic shape design

We investigate the performance of different variants of a suitably tailored Tabu Search optimisation algorithm on a higher-order design problem. We consider four objective func- tions to describe the performance of a compressor stator row, subject to a number of equality and inequality constraints. The same design problem has been previously in- vestigated through single-, bi- and three-objective optimisation studies. However, in this study we explore the capabilities of enhanced variants of our Multi-objective Tabu Search (MOTS) optimisation algorithm in the context of detailed 3D aerodynamic shape design. It is shown that with these enhancements to the local search of the MOTS algorithm we can achieve a rapid exploration of complicated design spaces, but there is a trade-off be- tween speed and the quality of the trade-off surface found. Rapidly explored design spaces reveal the extremes of the objective functions, but the compromise optimum areas are not very well explored. However, there are ways to adapt the behaviour of the optimiser and maintain both a very efficient rate of progress towards the global optimum Pareto front and a healthy number of design configurations lying on the trade-off surface and exploring the compromise optimum regions. These compromise solutions almost always represent the best qualitative balance between the objectives under consideration. Such enhancements to the effectiveness of design space exploration make engineering design optimisation with multiple objectives and robustness criteria ever more practicable and attractive for modern advanced engineering design. Finally, new research questions are addressed that highlight the trade-offs between intelligence in optimisation algorithms and acquisition of qualita- tive information through computational engineering design processes that reveal patterns and relations between design parameters and objective functions, but also speed versus optimum quality. © 2012 AIAA.

Detailed measurements of spike formation in an axial compressor

This paper presents new experimental measurements of spike-type stall inception. The measurements were carried out in the single stage Deverson compressor at the Whittle Laboratory. The primary objective was to characterize the flow field in the tip clearance gap during stall inception using sufficient instrumentation to give high spatial and temporal resolution. Measurements were recorded using arrays of unsteady pressure transducers over the rotor tips and hot-wires in the tip gap. Pre-stall ensemble averaged velocity and pressure maps were obtained as well as pressure contours of the stall event. In order to study the transient inception process in greater detail, vector maps were built up from hundreds of stalling events using a triggering system based on the stalling event itself. The results show an embryonic disturbance starting within the blade passage and leading to the formation of a clear spike. The origins of the spike and its relation to the tip leakage vortex are discussed. It has also been shown that before stall the flow in the blade passage which is most likely to stall is generally more unsteady, from revolution to revolution, than the other passages in the annulus. Copyright © 2012 by ASME.

Dynamic modelling of the brushless doubly fed machine

A coupled-circuit model for the brushless doubly fed machine (BDFM) has been developed. The transformation of the model into the d-q axis form, ultimately in a synchronous reference frame in which machine currents and voltages have constant values in the steady state, has been carried out. A model-reduction technique is presented, which gives a concise representation of the 'nested-loop' rotor design using a single d-q pair. These models have been experimentally verified and give a convenient and accurate way of calculating the dynamic behaviour of a BDFM. The ability to represent the BDFM with a single d-q pair considerably simplifies the design of suitable controllers. © The Institution of Engineering and Technology 2013.

Acoustic optimization of ultra-low count bypass outlet guide vanes

An optimization process has been used to design an ultra-low count fan outlet guide vane with an unconventional leading edge profile to reduce the interaction noise. Computational fluid dynamics has been used to predict the aerodynamic and acoustic performance of the stator vane. The final stator design has been built and tested in a representative fan stage rig to determine its tone noise characteristics. The stator vane is found to give significant tone noise reduction at the fundamental blade passing frequency at cut-back in line with design expectations. Detailed comparisons of predicted circumferential and radial modes levels against measured mode detection data are also presented. A good agreement was found between numerical predictions and experimental data.

Multi-objective optimisation of horizontal axis wind turbine structure and energy production using aerofoil and blade properties as design variables

The design of wind turbine blades is a true multi-objective engineering task. The aerodynamic effectiveness of the turbine needs to be balanced with the system loads introduced by the rotor. Moreover the problem is not dependent on a single geometric property, but besides other parameters on a combination of aerofoil family and various blade functions. The aim of this paper is therefore to present a tool which can help designers to get a deeper insight into the complexity of the design space and to find a blade design which is likely to have a low cost of energy. For the research we use a Computational Blade Optimisation and Load Deflation Tool (CoBOLDT) to investigate the three extreme point designs obtained from a multi-objective optimisation of turbine thrust, annual energy production as well as mass for a horizontal axis wind turbine blade. The optimisation algorithm utilised is based on Multi-Objective Tabu Search which constitutes the core of CoBOLDT. The methodology is capable to parametrise the spanning aerofoils with two-dimensional Free Form Deformation and blade functions with two tangentially connected cubic splines. After geometry generation we use a panel code to create aerofoil polars and a stationary Blade Element Momentum code to evaluate turbine performance. Finally, the obtained loads are fed into a structural layout module to estimate the mass and stiffness of the current blade by means of a fully stressed design. For the presented test case we chose post optimisation analysis with parallel coordinates to reveal geometrical features of the extreme point designs and to select a compromise design from the Pareto set. The research revealed that a blade with a feasible laminate layout can be obtained, that can increase the energy capture and lower steady state systems loads. The reduced aerofoil camber and an increased L/. D-ratio could be identified as the main drivers. This statement could not be made with other tools of the research community before. © 2013 Elsevier Ltd.

Electromagnetic-thermal design optimization of the brushless doubly fed induction generator

In view of its special features, the brushless doubly fed induction generator (BDFIG) shows high potentials to be employed as a variable-speed drive or wind generator. However, the machine suffers from low efficiency and power factor and also high level of noise and vibration due to spatial harmonics. These harmonics arise mainly from rotor winding configuration, slotting effects, and saturation. In this paper, analytical equations are derived for spatial harmonics and their effects on leakage flux, additional loss, noise, and vibration. Using the derived equations and an electromagnetic-thermal model, a simple design procedure is presented, while the design variables are selected based on sensitivity analyses. A multiobjective optimization method using an imperialist competitive algorithm as the solver is established to maximize efficiency, power factor, and power-to-weight ratio, as well as to reduce rotor spatial harmonic distortion and voltage regulation simultaneously. Several constraints on dimensions, magnetic flux densities, temperatures, vibration level, and converter voltage and rating are imposed to ensure feasibility of the designed machine. The results show a significant improvement in the objective function. Finally, the analytical results of the optimized structure are validated using finite-element method and are compared to the experimental results of the D180 frame size prototype BDFIG. © 1982-2012 IEEE.

The effect of clearance on shrouded and unshrouded turbines at two levels of reaction

In this paper, the effect of seal clearance on the efficiency of a turbine with a shrouded rotor is compared with the effect of the tip clearance when the same turbine has an unshrouded rotor. The shrouded versus unshrouded comparison was undertaken for two turbine stage designs one having 50% reaction, the other having 24% reaction. Measurements for a range of clearances, including very small clearances, showed three important phenomena. Firstly, as the clearance is reduced, there is a "break-even clearance" at which both the shrouded turbine and the unshrouded turbine have the same efficiency. If the clearance is reduced further, the unshrouded turbine performs better than the shrouded turbine, with the difference at zero clearance termed the "offset loss." This is contrary to the traditional assumption that both shrouded and unshrouded turbines have the same efficiency at zero clearance. The physics of the break-even clearance and the offset loss are discussed. Secondly, the use of a lower reaction had the effect of reducing the tip leakage efficiency penalty for both the shrouded and the unshrouded turbines. In order to understand the effect of reaction on the tip leakage, an analytical model was used and it was found that the tip leakage efficiency penalty should be understood as the dissipated kinetic energy rather than either the tip leakage mass flow rate or the tip leakage loss coefficient. Thirdly, it was also observed that, at a fixed flow coefficient, the fractional change in the output power with clearance was approximately twice the fractional change in efficiency with clearance. This was explained by using an analytical model. © 2014 by ASME.

Detailed measurements of spike formation in an axial compressor

This paper presents new experimental measurements of spike-type stall inception. The measurements were carried out in the single stage Deverson compressor at the Whittle Laboratory. The primary objective was to characterize the flow field in the tip clearance gap during stall inception using sufficient instrumentation to give high spatial and temporal resolution. Measurements were recorded using arrays of unsteady pressure transducers over the rotor tips and hot-wires in the tip gap. Prestall ensemble averaged velocity and pressure maps were obtained as well as pressure contours of the stall event. In order to study the transient inception process in greater detail, vector maps were built up from hundreds of stalling events using a triggering system based on the stalling event itself. The results show an embryonic disturbance starting within the blade passage and leading to the formation of a clear spike. The origins of the spike and its relation to the tip leakage vortex are discussed. It has also been shown that before stall, the flow in the blade passage which is most likely to stall is generally more unsteady, from revolution to revolution, than the other passages in the annulus. © 2014 by ASME.

Decoupling method for vector control of the brushless doubly-fed machine

The brushless doubly-fed machine exhibits rotor-speed-dependent, cross-coupling effects between inputs and outputs when vector control is implemented. Manipulation of the model equations shows that these effects are represented by rotation angles. A parameter-independent decoupling method is presented which reduces these cross-coupling disturbances by estimating the rotation angle and applying it back to the controller. © 2013 IEEE.

A study of converter rating for brushless DFIG wind turbines

This paper studies the converter rating requirement of a Brushless Doubly-Fed Induction Generator for wind turbine applications by considering practical constraints such as generator torque-speed requirement, reactive power management and grid low-voltage ride-through (LVRT). Practical data have been used to obtain a realistic system model of a Brushless DFIG wind turbine using steady-state and dynamic models. A converter rating optimization is performed based on the given constraints. The converter current and voltage requirements are examined and the resulting inverter rating is compared to optimization algorithm results. In addition, the effects of rotor leakage inductance on LVRT performance and hence converter rating is investigated.

On kinematic relaxation and deposition of water droplets in the last stages of low pressure steam turbines

In the first part of the paper steady two-phase flow predictions have been performed for the last stage of a model steam turbine to examine the influence of drag between condensed fog droplets and the continuous vapour phase. In general, droplets due to homogeneous condensation are small and thus kinematic relaxation provides only a minor contribution to the wetness losses. Different droplet size distributions have been investigated to estimate at which size inter-phase friction becomes more important. The second part of the paper deals with the deposition of fog droplets on stator blades. Results from several references are repeated to introduce the two main deposition mechanisms which are inertia and turbulent diffusion. Extensive postprocessing routines have been programmed to calculate droplet deposition due to these effects for a last stage stator blade in three-dimensions. In principle the method to determine droplet deposition by turbulent diffusion equates to that of Yau and Young [1] and the advantages and disadvantages of this relatively simple method are discussed. The investigation includes the influence of different droplet sizes on droplet deposition rates and shows that for small fog droplets turbulent diffusion is the main deposition mechanism. If the droplets size is increased inertial effects become more and more important and for droplets around 1 μm inertial deposition dominates. Assuming realistic droplet sizes the overall deposition equates to about 1% to 3% of the incoming wetness for the investigated guide vane at normal operating conditions. Copyright © 2013 by Solar Turbines Incorporated.

Water droplet flow paths and droplet deposition in low pressure steam turbines

The complex three-dimensional two-phase flow in a low pressure steam turbine is investigated with comprehensive numerical flow simulations. In addition to the condensation process, which already takes place in the last stages of steam turbines, the numerical flow model is enhanced to consider the drag forces between the droplets and the vapour phase. The present paper shows the differences in the flow path of the phases and investigates the effect of an increasing droplet diameter. For the flow simulations a performance cluster is used because of the high effort for such multi-momentum two-phase flow calculations. In steam turbines the deposition of small water droplets on the stator blades or on parts of the casing is responsible for the formation of large coarse water droplets and these may cause additional dissipation as well as damage due to blade erosion. A method is presented that uses detailed CFD data to predict droplet deposition on turbine stator blades. This simulation method to detect regions of droplet deposition can help to improve the design of water removal devices. © Springer-Verlag Berlin Heidelberg 2013.

Wave propagation in a slowly-varying duct with mean vortical swirling flow

The propagation of unsteady disturbances in a slowlyvarying cylindrical duct carrying mean swirling flow is investigated using a multiple-scales technique. This is applicable to turbomachinery flow behind a rotor stage when the swirl and axial velocities are of the same order. The presence of mean vorticity couples acoustic and vorticity equations which produces an eigenvalue problem that is not self-adjoint unlike that for irrotational mean flow. In order to determine the amplitude variation along the duct, an adjoint solution for the coupled system of equations is derived. The solution breaks down where a mode changes from cut on to cut off. In this region the amplitude is governed by a form of Airy's equation, and the effect of swirl is to introduce a small shift in the origin of the Airy function away from the turning-point location. The variation of axial wavenumber and amplitude along the duct is calculated. In hard-walled ducts mean swirl is shown to produce much larger amplitude variation along the duct compared with a nonswirling flow. Mean swirl also has a large effect in ducts with finite-impedance walls which differs depending on whether modes are co-rotating with the swirl or counter rotating. © 2001 by A.J. Cooper, Published by the American Institute of Aeronautics and Astronautics, Inc.