WO2019035811A1

WO2019035811A1 - Wireless power-transfer system for telemetry system in a high-temperature environment of a combustion turbine engine

Info

Publication number: WO2019035811A1
Application number: PCT/US2017/046908
Authority: WO
Inventors: Joshua S. MCCONKEY; John R. Fraley; Brett SPARKMAN
Original assignee: Siemens Energy Inc
Current assignee: Siemens Energy Inc
Priority date: 2017-08-15
Filing date: 2017-08-15
Publication date: 2019-02-21
Anticipated expiration: 2020-02-15

Abstract

A wireless power-transfer system as may be used in a telemetry system in a high-temperature environment of a combustion turbine engine is provided. A power-transmitting coil assembly (110) may be affixed to a stationary component (112) of the turbine engine proximate to a rotatable component (104) of the turbine engine. The power-transmitting coil assembly may include a plurality of annularly arranged wire-guiding segments (130) affixed to the stationary component of the turbine engine. Each wire-guiding segment may include a pair of parallel grooves (132) spaced apart from one another. A wire (140) is disposed in the pair of parallel grooves to form in a singular layer a power-transmitting coil (136) in response to an alternating current power signal supplied to the power-transmitting coil assembly to energize the wire.

Description

WIRELESS POWER- TRANSFER SYSTEM FOR TELEMETRY SYSTEM IN A HIGH-TEMPERATURE ENVIRONMENT OF

A COMBUSTION TURBINE ENGINE [0001] STATEMENT REGARDING FEDERALLY SPONSORED

DEVELOPMENT

[0002] Development for this invention was supported in part by Contract No. DE- FE0026348, awarded by the United States Department of Energy. Accordingly, the United States Government may have certain rights in this invention.

[0003] BACKGROUND

[0004] 1. Field

Disclosed embodiments are generally related to telemetry systems in a high- temperature environment, such as that of a combustion turbine engine, and, more particularly, to a wireless power transfer system for electrically powering circuitry of the telemetry system, such as may be disposed on a rotatable component of the turbine engine.

[0005] 2. Description of the Related Art

[0006] Combustion turbine engines, such as gas turbine engines, may be used in a variety of applications, such as driving an electric generator in a power generating plant or propelling a ship or an aircraft. Firing temperatures of modern gas turbine engines continue to increase in response to the demand for higher combustion efficiency.

[0007] It is desirable to use a wireless power transfer system, such as may be used for electrically powering circuitry of a telemetry system, which may be used to monitor operational parameters of the engine, such as monitoring operating temperature of components of the turbine, e.g., a turbine blade, or monitoring thermo-mechanical stresses placed upon such components during operation of the engine. [0008] Disclosed embodiments offer improvements in connection with a wireless power transfer system operating in the high-temperature, high g-force

environment of the turbine engine. See US patent 9,325,388 for one example of a wireless power transfer system involving a multi-layered winding architecture that may be configured to operate in the high-temperature, high g-force environment of the engine.

[0009] BRIEF DESCRIPTION [0010] One disclosed embodiment is directed to a wireless power-transfer system that includes a power-transmitting coil assembly affixed to a stationary component of the turbine engine proximate to a rotatable component of the turbine engine. The power-transmitting coil assembly may include a plurality of annularly arranged wire-guiding segments affixed to the stationary component of the turbine engine. Each wire-guiding segment may include a pair of parallel grooves spaced apart from one another. A wire is disposed in the pair of parallel grooves to form in a singular layer a power-transmitting coil in response to an alternating current power signal supplied to the power-transmitting coil assembly to energize the wire. [0011] In accordance with a further disclosed embodiment, a telemetry system for use in a combustion turbine engine may include a sensor on a turbine blade, a telemetry transmitter circuit connected to receive a signal from the sensor indicative of a condition of the turbine blade, and a wireless power-transfer system to power one or more circuitry of the telemetry system located on the turbine blade. The wireless power-transfer system may in turn include a power- transmitting coil assembly affixed to a stationary component proximate to the turbine blade. The power-transmitting coil assembly may include a plurality of annularly arranged wire-guiding segments affixed to the stationary component of the turbine engine. Each wire-guiding segment including a pair of parallel grooves spaced apart from one another, and a wire disposed in the pair of parallel grooves and forming in a singular layer a power-transmitting coil in response to an alternating current power signal supplied to the power-transmitting coil assembly to energize the wire. [0012] The wireless power-transfer system may further include a power-receiving coil assembly affixed to an end face of a root of the turbine blade. The power- receiving coil assembly may include a ceramic insulating body including a channel filled with high-purity silver configured to form a single-layer power- receiving coil inductively coupled to the power-transmitting coil. The telemetry system may further include a non-stationary antenna affixed to the end face of the root of the turbine blade. The telemetry transmitter circuit may be connected to the non-stationary antenna to transmit the signal indicative of the condition of the turbine blade, and a stationary antenna may be affixed to the stationary component to receive the signal indicative of the condition of the turbine blade.

[0013] BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a cross sectional view of one non-limiting example of a combustion turbine engine.

[0015] FIG. 2 is a block diagram representation of one non-limiting embodiment of a wireless telemetry system that can benefit from disclosed embodiments of a wireless power-transfer system.

[0016] FIG. 3 is a side view of a power-transmitting coil assembly that may be used in a disclosed wireless power-transfer system.

[0017] FIG. 4 is a side view illustrating further features in a disclosed power- transmitting coil assembly.

[0018] FIG. 5 is an isometric view comprising a power-receiving coil assembly that may be used in a disclosed wireless power-transfer system. [0019] FIG. 6 shows respective cross-sectional views of a power-transmitting coil assembly and a power-receiving coil assembly that may be used in a disclosed wireless power-transfer system. [0020] FIG. 7 is a fragmentary side view illustrating relative positioning between the power-transmitting coil assembly and a rotation path of the power-receiving coil assembly. [0021] FIG. 8 is a block diagram illustrating certain features of a disclosed wireless power-transfer system.

[0022] DETAILED DESCRIPTION [0023] The inventors of the present invention have recognized that a practical

limitation of certain known wireless power transfer systems designed for operating in the high-temperature, high g-forces environment of a gas turbine engine, is the difficulty of making resonating coils able to reliably operate in such a demanding environment while also enabling a substantially high quality (Q) factor for both the transmitter coil and the receiver coil.

[0024] As will be appreciated by one skilled in the art, the Q factor of a coil is the ratio of its inductive reactance to its resistance at a given frequency, and is a measure of its efficiency. For example, the relatively complex connectivity (as may involve integrated circuit (IC) fabrication techniques) utilized in the foregoing multi-layered winding architecture may not be conducive to achieving a substantially high Q factor, and thus may not be conducive to a wireless power transfer system having a high power transfer efficiency. [0025] In view of such recognition, the present inventors propose an innovative

wireless power-transfer system capable of efficient power transfer under challenging environmental conditions, such as may involve both high-temperature (without limitation, in the order of 550°C and higher) and high g-force (without limitation, turbine components can rotate at thousands of revolutions per minute (RPM) and thus subject to high g-forces). Disclosed embodiment of the wireless power-transfer system are conducive to reducing an air gap formed between the transmitting and receiving coils, which in turn is conducive to increase the level of power transfer. [0026] In the following detailed description, various specific details are set forth in order to provide a thorough understanding of such embodiments. However, those skilled in the art will understand that embodiments of the present invention may be practiced without these specific details, that the present invention is not limited to the depicted embodiments, and that the present invention may be practiced in a variety of alternative embodiments. In other instances, methods, procedures, and components, which would be well-understood by one skilled in the art have not been described in detail to avoid unnecessary and burdensome explanation. [0027] Furthermore, various operations may be described as multiple discrete steps performed in a manner that is helpful for understanding embodiments of the present invention. However, the order of description should not be construed as to imply that these operations need be performed in the order they are presented, nor that they are even order dependent, unless otherwise indicated. Moreover, repeated usage of the phrase "in one embodiment" does not necessarily refer to the same embodiment, although it may. It is noted that disclosed embodiments need not be construed as mutually exclusive embodiments, since aspects of such disclosed embodiments may be appropriately combined by one skilled in the art depending on the needs of a given application.

[0028] The terms "comprising", "including", "having", and the like, as used in the present application, are intended to be synonymous unless otherwise indicated. Lastly, as used herein, the phrases "configured to" or "arranged to" embrace the concept that the feature preceding the phrases "configured to" or "arranged to" is intentionally and specifically designed or made to act or function in a specific way and should not be construed to mean that the feature just has a capability or suitability to act or function in the specified way, unless so indicated.

[0029] FIG. 1 illustrates a non-limiting example of a combustion turbine engine 10, such as a gas turbine engine, as may be used for generating electricity. Disclosed embodiments may be used in a combustion turbine 10 or in numerous other operating environments and for various purposes, such as for aerospace applications. [0030] Combustion turbine engine 10 may include a compressor 12, at least one combustor 14 (fragmentarily illustrated) and a turbine 16. Compressor 12, combustor 14 and turbine 16 are sometimes collectively referred to as a gas or combustion turbine engine 10. Turbine 16 includes a plurality of rotating blades 18, secured to a rotatable central shaft 20. A plurality of stationary vanes 22 may be positioned between blades 18, with vanes 22 being dimensioned and

configured to guide air over blades 18. Blades 18 and vanes 22 may be typically made from nickel-based alloys, and may be coated with a thermal barrier coating ("TBC") 26, such as without limitation, yttria-stabilized zirconia. Similarly, compressor 12 includes a plurality of rotating blades 19 positioned between respective vanes 23.

[0031] FIG. 2 is a block diagram schematic representation of a non-limiting

embodiment of a wireless telemetry system 100 system that can benefit from disclosed embodiments. A sensor 102 may be disposed on a movable component

104 of the turbine engine (e.g., a non-stationary turbine blade). A telemetry transmitter circuit 106 may be connected to sensor 102 to receive from sensor 102 a data signal, such as a signal indicative of a condition of movable component 104. This signal is then transmitted to a non- stationary antenna 142 on movable component 104.

[0032] As elaborated in greater detail below, a wireless power-transfer system 108 may be arranged to wirelessly supply electrical power to circuitry on the movable component, e.g., telemetry transmitter circuit 106, sensor 102, etc. Wireless power-transfer system 108 may include a power-transmitting coil assembly 110 affixed to a stationary component 112 of the turbine engine. Stationary component 112 may be located proximate to movable component 104. A stationary antenna 144 may be affixed to stationary component 112 to receive from non- stationary antenna 142 the signal indicative of the condition of movable component 104. [0033] Power-transmitting coil assembly 110 may be connected to receive electrical power from an alternating current (AC) power source 114 to generate an oscillating electromagnetic field so that electrical energy may be inductively coupled in a non-stationary power-receiving coil assembly 116 arranged to supply electrical power to circuitry on movable component 104. In one non-limiting embodiment, power-receiving coil assembly 116 may be affixed to an end face 120 (FIG. 6) of a root 122 of movable component 104, e.g., a turbine blade.

[0034] In operation, air is drawn in through compressor 12, where it is compressed and conveyed to combustor 14. Combustor 14 mixes the air with fuel and ignites it thereby forming a working gas. This working gas temperature will typically be above about 1300°C. This gas expands through turbine 16, being guided across blades 18 by vanes 22. As the gas passes through turbine 16, it rotates blades 18 and shaft 20, thereby transmitting usable mechanical work through shaft 20. Combustion turbine 10 may also include a cooling system (not shown), dimensioned and configured to supply a coolant, for example, compressed air, to blades 18 and vanes 22.

[0035] The environment within which turbine blades 18 and vanes 22 operate is particularly harsh, subject to high operating temperatures and a corrosive atmosphere, which may result in serious deterioration of blades 18 and vanes 22. This is especially likely if TBC 26 should spall or otherwise deteriorate. A plurality of sensors 50 may be used for detecting a condition of the blades and/or vanes. Disclosed embodiments are advantageous because telemetry circuitry may transmit in real time or near real time data indicative of a component's condition during operation of combustion turbine 10.

[0036] As may be appreciated in FIG. 3, in one non-limiting embodiment, power- transmitting coil assembly 110 includes a plurality of annularly arranged wire- guiding segments 130 affixed to stationary component 112 (FIG. 2) of the turbine engine. Without limitation, each wire-guiding segment 130 may include a pair of parallel grooves 132, such as may be radially spaced apart from one another. In one non-limiting embodiment, wire-guiding segments 130 may be affixed to the stationary component by way of bolts 134 or any other suitable affixing mechanism, and may be made of a silicate alumina refractory that may be machined or cast to a desired configuration. In one non-limiting embodiment, one of the wire-guiding segments may include a wire entrance groove 135 and a wire exit groove 138. This wire-guiding segment may further include a wire loopback groove 141. The functionality of the various grooves in wire-guiding segments

130 will be apparent from the description that follows.

[0037] As shown in FIG. 4, a wire 140 is disposed (e.g., following a path to form a loop) in the various grooves constructed in the annularly arranged wire-guiding segments 130 to form, in a singular layer air core, a power-transmitting coil 136 in response to an AC power signal supplied to power-transmitting coil assembly to energize wire 140. That is, wire 140 is routed in the annularly arranged wire- guiding segments 130 to form coil loop arrangement, such as illustrated in FIG. 4. The foregoing coil loop arrangement should not be construed in a limiting sense since other coil loop arrangements may be tailored based on the needs of a given application.

[0038] As will be appreciated by those skilled in the art, power-transmitting coil 136 being a singular layer air core coil is advantageously free of the "iron

losses" which affect ferromagnetic cores, and has the additional advantage of having a relatively low self-capacitance value, and is thus conducive to a high self-resonant frequency. The foregoing is in turn effective for high frequency (HF) operation, such as radio frequency electromagnetic waves (e., radio waves) in a range from 3 MHz to 30 MHZ. Without limitation, in addition to ease of manufacturing in connection with power-transmitting coil 136, one can obtain a substantially high Q-factor, greater efficiency and greater power-transfer handling compared to, for example, a multi-layered, winding architecture that may involve a relatively complex connectivity. [0039] Without limitation, wire 140 may be a high-temperature, stranded wire effective for HF operation and having a sufficient gauge size to meet the current- carrying needs that may be involved in a given application while enabling a substantially high Q factor in power-transmitting coil 136. Without limitation, wire 140 can be a nickel-plated, copper wire, and insulation that may be optionally used (e.g., a wire jacket) may comprise fiberglass and ceramic braids. In one non-limiting embodiment, each wire-guiding segment 130 may include a respective lid 143 to retain wire 140 in power-transmitting coil assembly 110. Without limitation, lid 143 may be made from a ceramic matrix composite (CMC) or an alumina-based high-strength ceramic effective to mitigate thermal expansion.

[0040] As may be appreciated in FIG. 5, in one non-limiting embodiment, power- receiving coil assembly 116 may comprise a ceramic insulating body 150, such as a low-temperature co-fired ceramic (LTCC) or a high-temperature co-fired ceramic (HTCC). In one non-limiting embodiment, ceramic insulating body 150 includes a channel 152 filled with a highly electrically conductive material, such as without limitation high-purity silver, configured to form, in a single-layer air core, a power-receiving coil 154 inductively coupled to power-transmitting coil 136. Without limitation, power-receiving coil 154 may be a rectangular-shaped power-receiving coil. In one non-limiting embodiment, ceramic insulating body

150 and power-receiving coil 154 may comprise a monolithic body, which is conducive to superior reliability under challenging environmental conditions, such as both high-temperature and high g-force. [0041] FIG. 6 shows respective cross-sectional views of power-transmitting coil

assembly HOand power-receiving coil assembly 116. In one non-limiting embodiment, one or more circuitry of telemetry system (schematically represented by blocks 156) may be collocated in power-receiving coil assembly 116 jointly with power-receiving coil 154. This is conducive for making electrical

interconnections between power-receiving coil 154 and circuitry 156 when power- receiving coil assembly 116 is being manufactured since, in this case, power- receiving coil 154 and circuitry 156 share a common assembly. This eliminates a need of having to perform such interconnections in the field, as would be the case if the power-receiving coil and such circuitry did not share a common assembly. [0042] As may be further appreciated in FIG. 6, in one non-limiting embodiment, a ceramic fabric 155, such as alumina fabric or Nextel fabric, may be interposed between respective mutually engaging surfaces 157, 158 of the stationary component of the turbine engine and wire-guiding segments

130. Similarly, another ceramic fabric 155 may be interposed between respective mutually engaging surfaces 160, 162 of the rotatable component of the turbine engine and a housing 164 that accommodates power-receiving coil assembly 116. In each instance, ceramic fabric 155 may be effective to provide vibrational buffering between such mutually engaging surfaces.

Housing 164 may include a lid 166 to securely retain power-receiving coil assembly 116. Without limitation, housing 164 and lid 166 may be made from a ceramic matrix composite (CMC) or an alumina-based high-strength ceramic, such as without limitation, strengths of approximately 600 MPa and

1 /9 over, and a high fractural toughness (e.g., approximately 6-7 MPa.m and over) in the high-temperature environment.

[0043] As may be appreciated in FIG. 7, in one non-limiting embodiment, where a center of a rotation path (schematically represented by the cross mark x) of power- receiving coil 154 may be in correspondence with a midline 168 interposed between a radial gap 170 defined by the parallel grooves where wire 140 is disposed. Due to the relatively large areas respectively encompassed by power- transmitting coil 136 and power-receiving coil 154, it will be appreciated that some shift in the relative positioning between power-transmitting coil 136 and power-receiving coil 154 would not compromise the power transfer capabilities of wireless power-transfer system 108.

[0044] FIG. 8 is a block diagram illustrating certain features of wireless telemetry system 100. In one non-limiting embodiment, a tunable circuit 200 may be configured to match impedance (e.g., dynamically matching impedance) between power source 114, which supplies the alternating power signal to energize power- transmitting coil 136 (e.g., wire 140 in FIG. 4). [0045] This is effective to ensure consistent repeatability of power transfer efficiency in wireless power-transfer system 108 (FIG. 2) regardless of different turbine engine configurations where wireless power-transfer system 108 may be installed. For example, load impedance (e.g., relative to power source 114) could change depending on the structural configuration of a given engine. A variety of techniques may be used to perform the foregoing match impedance, such as may be based on monitoring a Standing Wave Ratio (SWR), which, as would be appreciated by one skilled in the art, is a function of a reflection coefficient indicative of reflected power that may change based on impedance mismatches between a source and a load.

[0046] In one non-limiting embodiment, because of the advantageous collocation of circuitry 156 (FIG. 6) and power-receiving coil 154 in power-receiving coil assembly 116, this allows a relatively larger footprint for this assembly. For example, a resonating capacitor 204 (FIG. 8) can be directly connected (i.e., without an intermediate connecting link) onto terminating leads of power- receiving coil 154, which is conducive to a higher Q factor, such as due to decreased parasitics. A rectifier 206 may be connected to power-receiving coil 154 to supply the Direct Current (DC) voltage output suitable for powering the various circuitries in wireless telemetry system 100.

[0047] In operation, disclosed embodiments provide in a cost-effective manner, a robust, wireless power-transfer system capable of efficient power transfer while subject to temperatures in the order of 550°C and higher. Without limitation, it has been experimentally demonstrated with a disclosed wireless power-transfer system a power transfer of approximately 30 W over an air gap of approximately 45 mm, which is approximately an order of magnitude improvement over a known wireless power-transfer system. Disclosed embodiments are effective for implementing a simpler, yet robust coil architecture conducive to uncomplicated installation and efficient operation of a wireless power-transfer system in a gas turbine engine. Disclosed embodiments are additionally conducive to user- friendly operations, such as in connection with servicing operations that may be performed during the operational lifetime of the wireless power-transfer system. 8] While embodiments of the present disclosure have been disclosed in exemplary forms, it will be apparent to those skilled in the art that many modifications, additions, and deletions can be made therein without departing from the scope of the invention and its equivalents, as set forth in the following claims.

Claims

What is claimed is:

1. In a telemetry system in a high-temperature environment of a combustion turbine engine, a wireless power-transfer system comprising:

a power-transmitting coil assembly affixed to a stationary component of the turbine engine proximate to a rotatable component of the turbine engine, the power- transmitting coil assembly comprising:

a plurality of annularly arranged wire-guiding segments affixed to the stationary component of the turbine engine;

each wire-guiding segment including a pair of parallel grooves spaced apart from one another; and

a wire disposed in the pair of parallel grooves and forming in a singular layer a power-transmitting coil in response to an alternating current power signal supplied to the power-transmitting coil assembly to energize the wire.

2. The wireless power-transfer system of claim 1, wherein the alternating current power signal supplied to the power-transmitting coil assembly comprises a high frequency (HF) range.

3. The wireless power-transfer system of claim 1, wherein each of the wire- guiding segments comprises a silicate alumina refractory.

4. The wireless power-transfer system of claim 1, wherein one of the wire- guiding segments includes a wire entrance groove and a wire return groove.

5. The wireless power-transfer system of claim 4, wherein said one of the wire- guiding segments further includes a wire loopback groove.

6. The wireless power-transfer system of claim 1, further comprising a ceramic fabric interposed between respective mutually engaging surfaces of the stationary component of the turbine engine and the wire-guiding segments.

7. The wireless power-transfer system of claim 1, wherein the wire comprises a stranded wire.

8. The wireless power-transfer system of claim 7, wherein the stranded wire comprises a nickel-coated copper wire.

9. The wireless power-transfer system of claim 1, further comprising a power- receiving coil assembly affixed to the rotatable component of the turbine engine, the power-receiving coil assembly comprising a ceramic insulating body including a channel filled with high-purity silver configured to form a single-layer power- receiving coil inductively coupled to the power-transmitting coil.

10. The wireless power-transfer system of claim 9, wherein the ceramic insulating body and the power-receiving coil comprise a monolithic body.

11. The wireless power-transfer system of claim 9, wherein the power-receiving coil comprises a rectangular- shaped power-receiving coil and a center of a rotation path of the rectangular- shaped power-receiving coil is in correspondence with a midline between the pair of parallel grooves where the wire that forms the power- transmitting coil is disposed.

12. The wireless power-transfer system of claim 1, further comprising a tunable circuit configured to match impedance between a power source that supplies that supplies the alternating power signal to energize the wire in the power-transmitting coil assembly.

13. The wireless power-transfer system of claim 9, wherein one or more circuitry of the telemetry system is collocated in the power-receiving coil assembly with the power-transmitting coil.

14. The wireless power-transfer system of claim 9, wherein the power-receiving coil assembly includes a resonating capacitor directly connected to the power- receiving coil.

15. The wireless power-transfer system of claim 9, wherein the power- transmitting coil assembly comprises a lid to retain the wire disposed in the pair of parallel grooves, the lid comprising a material selected from the group consisting of a ceramic matrix composite and an alumina-based high-strength ceramic.

16. A telemetry system for use in a combustion turbine engine, the telemetry system comprising:

a sensor on a turbine blade;

a telemetry transmitter circuit connected to receive a signal from the sensor indicative of a condition of the turbine blade;

a wireless power-transfer system to power one or more circuitry of the telemetry system located on the turbine blade, the wireless power-transfer system comprising:

a power-transmitting coil assembly affixed to a stationary component proximate to the turbine blade, the power-transmitting coil assembly comprising:

a wire disposed in the pair of parallel grooves and forming in a singular layer a power-transmitting coil in response to an alternating current power signal supplied to the power-transmitting coil assembly to energize the wire; and

a power-receiving coil assembly affixed to an end face of a root of the turbine blade, the power-receiving coil assembly comprising:

a ceramic insulating body including a channel filled with high- purity silver configured to form a single-layer power-receiving coil inductively coupled to the power-transmitting coil;

a non-stationary antenna affixed to the end face of the root of the turbine blade, wherein the telemetry transmitter circuit is connected to the non-stationary antenna to transmit the signal indicative of the condition of the turbine blade; and a stationary antenna affixed to the stationary component to receive the signal indicative of the condition of the turbine blade.

17. The wireless power-transfer system of claim 16, wherein the alternating current power signal supplied to the wire comprises a high frequency (HF) range.

18. The wireless power-transfer system of claim 16, further comprising a tunable circuit configured to match impedance between a power source that supplies the alternating power signal to energize the wire in the power-transmitting coil assembly.

19. The wireless power-transfer system of claim 16, wherein each of the wire- guiding segments comprises a silicate alumina refractory, and the wire comprises a stranded wire.

20. The wireless power-transfer system of claim 16, wherein the ceramic insulating body and the power-receiving coil comprise a monolithic body configured for collocating one more circuitry of the telemetry system with the power-transmitting coil in the power-receiving coil assembly.