Prototyping of ultra micro centrifugal compressor-influence of meridional configuration

In order to investigate the design method for a micro centrifugal compressor,which is the most important component of an ultra micro gas turbine,two types of centrifugal impeller with 2-dimensional blade were designed,manufactured and tested.These impellers have different shapes of hub on the meridional plane with each other.Moreover,these types of impeller were made for the 5 times and the 6 times size of the final target centrifugal impeller with the outer diameter of 4mm in order to assess the similitude...     

Design and Prototyping of Micro Centrifugal Compressor

In order to establish the design methodology of ultra micro centrifugal compressor, which is the most important component of ultra micro gas turbine unit, a 10 times of the final target size model was designed, prototyped and tested. The problems to be solved for downsizing were examined and 2-dimensional impeller was chosen as the first model due to its productivity. The conventional ID prediction method, CFD and the inverse design were attempted. The prototyped compressor was driven by using a turbocharger and the performance characteristics were measured.     

Investigation of Surge Behavior in a Micro Centrifugal Compressor

This paper reports the experimental and theoretical study of the surge occurred in prototyping an ultra micro centrifugal compressor. As the first step, the 10 times size model of an ultra micro centrifugal compressor having the 40 mm outer diameter was designed and manufactured. The detailed experimental investigations for the transient behavior of surge with several different values of B parameter were carried out. The experimental results during the surge were compared with those obtained by the non-linear lumped parameter theory in order to validate the effectiveness of the theoretical surge model for the micro centrifugal compressor. As a result, the quite different behavior of the surge appeared for the different values of B both in the experiment and in the analysis.     

Numerical analysis of flow in ultra micro centrifugal compressor -influence of meridional configuration

A single stage ultra micro centrifugal compressor constituting ultra micro gas turbine is required to operate at high rotational speed in order to achieve the pressure ratio which establishes the gas turbine cycle. As a consequence, the aerodynamic losses can be increased by the interaction of a shock wave with the boundary layer on the blade surface. Moreover, the centrifugal force which exceeds the allowable stress of the impeller material can act on the root of blades. On the other hand, the restrictions of processing technology for the downsizing of impeller not only relatively enlarge the size of tip clearance but also make it difficult to shape the impeller with the three-dimensional blade. Therefore, it is important to establish the design technology for the impeller with the two-dimensional blade which possesses the sufficient aerodynamic performance and enough strength to bear the centrifugal force caused by the high rotational speed. In this study, the flow in two types of impeller with the two-dimensional blade which have different meridional configuration was analyzed numerically. The computed results clarified the influence of the meridional configuration on the loss generations in the impeller passage.     

Experimental Investigations of Micro Air Injection to Control Rotating Stall

Steady discrete micro air injection at the tip region in front of the first compressor rotor has been proved to be aneffective method to delay the inception of rotating stall in a low speed axial compressor.Considering the practicalapplication a new type of micro injector was designed and described in this paper,which was imbedded in thecasing and could be moved along the chord.In order to verify its feasibility to other cases,such as high subsonicaxial compressor or centrifugal compressor,some other cases have been studied.Experimental results of the samelow speed axial compressor showed that the new injector could possess many other advantages besides success-fully stabilizing the compressor.Experiments performed on a high subsonic axial compressor confirmed the ef-fectiveness of micro air injection when the relative velocity at the blade tip is high subsonic.Meanwhile in orderto explore its feasibility in centrifugal compressor,a similar micro injector was designed and tested on a lowspeed centrifugal compressor with vaned diffuser.The injected mass flow was a bit larger than that used in axialcompressors and the results showed micro injection could also delay the onset of rotating stall in the centrifugalcompressor.     

Experimental investigation of a novel micro gas turbine with flexible switching function for distributed power system

Micro gas turbine (MGT) is widely used in small-scale distributed power systems because of its low emissions and fuel flexibility. However, the under-utilization of its exhaust heat and the low electric efficiency are the main bottlenecks that restrict its application. Additionally, the flexible switching between the power generated by the MGT and the power grid is also a key factor for keeping the secure operation of a distributed power station. Therefore, this paper conducted some experimental investigations of a 30 kW MGT to provide reference solutions for the above issues. This MGT is located at Shanghai Jiao Tong University (SJTU), which is designed by the Gas Turbine Research Institute of SJTU, and is manufactured by a turbo-machinery factory in Chongqing, China. The demonstration prototype is mainly composed of a single stage centrifugal compressor, a radial turbine, a combustor, a high-speed permanent magnet generator, and a control system. The results show that the MGT can achieve steady operation at a low rotational speed from 10000 r/min to 34000 r/min in the case of using oil lubricated bearings, which can greatly reduce the economic cost compared with the use of air bearings. At the same time, the ignition success rate of combustion chamber (CC) reaches 98% at a low rotational speed, and a wide range of stable combustion area can be obtained, because of the novel design method of combustor by referencing the way applied in an axial flow aero-engine. The MGT generating set can achieve functions, such as starting up, ignition, stable operation, loaded operation, grid-connection and stopping. This system also can realize flexibly switching from the start motor mode to the generator mode, and from grid-connected mode to off-grid mode, because the innovative multi-state switching control system is adopted. The above research work can make our state master independent intellectual property rights of micro gas turbine, rather than continue to be subject to the technological monopoly of the developed states, which can provide theoretical and experimental support for the industrialization of MGT in China.     

Investigation of a centrifugal compressor and study of the area ratio and TIP clearance effects on performance

In this research, the centrifugal compressor of a turbocharger is investigated experimentally and numerically. Performance characteristics of the compressor were obtained experimentally by measurements of rotor speed and flow parameters at the inlet and outlet of the compressor. Three dimensional flow field in the impeller and dif- fuser was analyzed numerically using a full Navier-Stokes program with SST turbulence model. The performance characteristics of the compressor were obtained numerically, which were then compared with the experimental results. The comparison shows good agreement. Furthermore, the effect of area ratio and tip clearance on the performance parameters and flow field was stud- ied numerically. The impeller area ratio was changed by cutting the impeller exit axial width from an initial value of 4.1 mm to a final value of 5.1 mm, resulting in an area ratio from 0.792 to 0.965. For the rotor with exit axial width of 4.6 mm, performance was investigated for tip clearance of 0.0, 0.5 and 1.0 mm. Results of this simula- tion at design point showed that the compressor pressure ratio peaked at an area ratio of 0.792 while the effi- ciency peaked at a higher value of area ratio of 0.878. Also the increment of the tip clearance from 0 to 1 mm resulted in 20 percent efficiency decrease.     

单叶片强度分析及整圈叶片动频计算

根据国内外同行多年设计经验,综合考虑安全性、经济性与工艺性,设计了1200mm长叶片的结构。在此基础上,应用有限元方法,建立了单叶片的有限元模型,在3300 r/min超速运行条件下,分析了叶片的静应力。计算结果表明,在超速情况下叶片强度是安全的;应用有限元商用软件ANSYS,采用接触边界法,建立了整圈叶片模型,计算了整圈叶片的动频率,得到叶轮的三重点共振转速M3为2802 r/min,由于叶片的工作转速为2820 r/min~3 090r/min,因此在该区间无三重点共振,叶片振动是安全的。     

贫燃催化燃烧燃气轮机压气机的设计及其性能分析

分析了贫燃催化燃烧燃气轮机系统中压气机的结构特点,设计了低出口宽径比、高比转速的压气机叶轮,并采用数值计算和试验2种方法预测了其工作性能.结果表明:数值计算与试验结果基本吻合,该压气机在全工况下达到设计要求,且2种结果的高压比区域、高效率区域均远离喘振线;低宽径比、高比转速压气机的设计点在高效区;随着转速的提高,此压气机的压比特性曲线在小流量区增长的趋势明显;采用低宽径比、高比转速设计的负面作用是增大了叶尖相对马赫数.     

Overall Thermodynamic Model of an Ultra Micro Turbine

The overall thermodynamic model of an ultra micro turbine engine has been established and applied in different situations in this tiny engine where heat transfer is dominant. The aerothermal conditions of the flow were calculated and analyzed. A corresponding calculation software (hot button software) was developed. The first results show that the non-adiabatic operation of the turbomachines leads to a strong penalty in performances. The dramatic influence of the compressor and turbine efficiency is confirmed in a non-adiabatic operation. A better knowledge of heat transfer coefficients at low Reynolds numbers in different components of the micro turbine has to be obtained to refine the results of this study.     

分体式燃气轮机的变工况性能分析

采用商业软件Thermoflex对分体式燃气轮机进行模拟,建立了系统的性能分析模型,分析指出压气机转速、透平转速和燃气初温是影响系统变工况性能的主要因素,并对转速和燃气初温变化时系统的输出性能进行了计算分析.通过和共轴燃机的比较分析,得出了分体式燃气轮机的性能潜力.     

Manipulation of micro solid particles and induced flows in water by laser irradiation

Q-switch for pulsing laser beam and Galvano scanner for rapid scanning laser beam were adapted to manipulatemicro solid particles in a water droplet.The trapping of fine particles at micron-sized diameters by a YAG lasersystem,induced flows,and the induced motion of the particles by laser beam irradiations are discussed.Particlerotations are observed by using anisotropic micro objects,and moreover the rotational rate with clockwise direc-tion is 22 r/min.The fragments of a cover glass were mixed in a water droplet,and their size and shape are un-even.The rotation of that non-spheres without scanning by the Galvano scanner is also observed in water.     

增压器压气机三体接触问题的研究

涡轮增压器是机车柴油机的重要部件之一。增压器压气机叶轮、轴套和轴采用过盈配合技术联成一体,这是典型的三维多体接触问题。以某柴油机涡轮增压器的压气机为例,采用有限元参数二次规划法,并结合多重子结构技术分析求解叶轮与轴套、轴套与轴的三维弹性接触问题,利用JIFEX程序,针对不同的过盈量、转速和轴套壁厚进行了大量计算,获得了叶轮、轴套与轴之间接触应力的相应分布规律,以作为设计、制造时参考。     

Radial Forces in a Centrifugal Compressor; Experimental Investigation by Using Magnetic Bearings and Static Pressure Distribution

The volute of a centrifugal compressor causes a non-uniform pressure distribution which leads to a radial force on the impeller. This force was measured using magnetic bearings. In addition, the radial force was estimated using the static pressure distribution measured at the impeller outlet. The impeller force was found to be the highest at choke, the lowest at the design flow and moderate at stall. The radial force determined from the pressure measurements was only slightly different from the force obtained from the bearing measurements. The rotational speed was seen to affect the force to some extent.     

Multiphysics Design of a High-Speed Permanent Magnet Machine for a Micro Gas Turbine Application

This paper presents a detailed and comprehensive multiphysics design process of an 80 kW, 60 000 r/min high-speed permanent magnet machine (HSPMM) for a micro gas turbine application. First, the preliminary design of the HSPMM is carried out according to the mechanical and electromagnetic theory. Afterwards, the influence of carbon fiber sleeve (CFS) thickness, rotor diameter and core length on rotor stress and rotor dynamics is carefully analyzed to obtain the optimal range of rotor diameter and core length. On this basis, the electromagnetic and power loss characteristics are analyzed in detail to obtain the final design scheme. Fluid-solid coupling model is used to calculate the temperature field of the HSPMM to verify the rationality of the scheme. The rotor thermal stress analysis considering the multi-layer and multi-angle winding of CFS is carried out to obtain the rotor models suitable for prototype and mass production, respectively. Finally, the prototypes are manufactured and tested to verify the reliability of the multiphysics design process.     

Thermodynamic optimization for an open cycle of an externally fired micro gas turbine (EFmGT). Part 1: Thermodynamic modelling

The principle of optimally tuning the air flow rate and subsequent distribution of pressure drops is applied to optimize the performance of a thermodynamic model for an open regenerative cycle of an externally fired micro gas turbine power plant with pressure drop irreversibilities by using finite-time thermodynamics and considering the size constraints of the real plant. There are eight flow resistances encountered by the working fluid stream for the cycle model. Two of these, the friction through the blades and vanes of the compressor and the turbine, are related to the isentropic efficiencies. The remaining flow resistances are always present because of the changes in flow cross-section at the compressor inlet and outlet, the turbine inlet and outlet and the regenerator hot/cold-side inlet and outlet. These resistances associated with the flow through various cross-sectional areas are derived as functions of the compressor inlet relative pressure drop, and control the air flow rate and the net power output and thermal efficiency. The analytical formulae for the power output, efficiency and other coefficients are derived, which indicate that the thermodynamic performance for an open regenerative cycle of an externally fired micro gas turbine power plant can be optimized by adjusting the mass flow rate (or the distribution of pressure losses along the flow path). It is shown that there are optimal air mass flow rates (or the distribution of pressure losses along the flow path) which maximize the net power output.     

Shape optimization of cut-off in a multi-blade fan/scroll system using neural network

In order to improve efficiency of a system with three-dimensional flow characteristics, this paper presents a new method that overcomes the computational difficulties associated with three-dimensional effects by using two-dimensional CFD and a neural network. The method was applied to the shape optimization of cut-off in a multi-blade fan/scroll system. As for the entrance conditions of two-dimensional CFD analysis, the experimental values at the positions apart from the inactive zone were used. The distributions of velocity and pressure obtained by two-dimensional CFD analysis were compared with those of three-dimensional CFD analysis and experimental results. It was found that the distributions of velocity and pressure have qualitative similarity. The results of two-dimensional CFD analysis were used for learning as target values of a neural network. The optimal angle and radius of cut-off were determined as 71° and 0.092 times the outer diameter of impeller, respectively. It was concretized in a previous report that the optimal angle and radius of cut-off are approximately 72° and 0.08 times the outer diameter of impeller, respectively.     

静止液体中浸没垂直导管口气泡形成实验

利用高速摄像技术研究气流通过浸没垂直导管口在液体中形成气泡的机理及其行为规律,分析导管内径、气体流量、导管口浸没深度和导管外径对气泡脱离直径的影响。结果表明:在导管内径分别为7、10和14 mm,气体流量在0~450 mL/s的条件下,气泡脱离直径随导管内径和气体流量的增加而增大;在浸没深度为0.05~1 m的条件下,导管口浸没深度对气泡脱离直径的影响很小可以忽略;当气体流量在100 mL/s以上,导管内径为10 mm、导管外径为14~26 mm时,随着导管外径的增加,气泡脱离直径减小。     

Power generation performance of hydrogen-fueled micro thermophotovoltaic reactor

A tubular platinum reactor with a perforated annular array enables fuel/air mixtures to exchange sides, thus sustaining flames and preventing heat loss. Consequently, the combustion efficiency and operational range can be enhanced. A hydrogen/air mixture was introduced into inner and outer chambers at different equivalence ratios and flow velocities to chemically and physically investigate the interplay between the chambers. The benefits of hydrogen include a high gravimetric heating value, flame speed, and diffusion capacity and short chemical reaction time. The coexistence of heterogeneous (surface) and homogeneous (gas) reactions in the micro TPV reactor was examined and elucidated in terms of aerodynamics, mass and heat transfer, and chemical reactivity. Furthermore, a TPV reactor with TPV cell arrays was assembled, and the corresponding radiant efficiency of the emitter and the overall efficiency of the proposed micro TPV system were determined in this study.     

Investigation of a miniature centrifugal fan

A centrifugal fan was designed with a matching centrifugal volute flow channel in order to investigate a numerical simulation with prototype manufacturing, and to compare with experimental results. The fan configuration was developed according to a fan-design theorem. A model P-60 turbojet engine compressor blade design was adopted for the fan aerodynamic analysis and design. The results were verified using the STAR-CD code. Also, based on the findings, a miniature centrifugal fan was designed and manufactured using a CNC five axes machine. The P–Q performance curves were tested using an AMCA standard 210-85 test chamber apparatus. From the numerical analysis results, the pressure on the suction and pressure surfaces will increase gradually from the inlet to one-half the distance of the hub’s camber line, however, it will increase more rapidly afterwards. In addition, stress-concentration phenomenon occurred at the tip of the suction and pressure surfaces. In other words, the tip was more prone to damage when the fan was operated. Experiments show that the designed fan maximum flow rate Q and static pressure P were 32% and 59%, respectively, which were lower than the commercial fan data at 2000 rpm rotational speed. However, when the rotational speed was increased to 4000 rpm, the maximum flow rate Q and static pressure P were increased to 38% and 82%. This study concluded that a centrifugal fan’s static pressure at high rotational speed is higher than that of an axial-flow fan. Therefore, a centrifugal fan should be chosen if high static pressure cooling or blowing is required. This advanced research investigation is to build up the capabilities of design, analysis, manufacturing, and measurement of a centrifugal fan with an outer diameter smaller than 10 cm.