WO2019147229A1

WO2019147229A1 - Wide-bandgap integrated circuitry for wireless telemetry in a high-temperature environment of turbomachinery

Info

Publication number: WO2019147229A1
Application number: PCT/US2018/014998
Authority: WO
Inventors: Joshua S. MCCONKEY; John R. Fraley; Brett SPARKMAN
Original assignee: Siemens Energy, Inc.
Priority date: 2018-01-24
Filing date: 2018-01-24
Publication date: 2019-08-01

Abstract

Wireless telemetry system (100) that makes use of integrated wide-bandgap semiconductor technology in a high-temperature environment of a gas turbine engine is disclosed. A wide-bandgap integrated circuitry (WBIC) (98) includes a telemetry transmitter circuitry (106) connected to receive a sensor signal indicative of a condition of the turbine blade. The WBIC may further include power-conditioning circuitry (150) to condition power in a power transfer system (108). A non-stationary antenna (142) may be affixed to the turbine blade. The telemetry transmitter circuitry is connected to the non-stationary antenna to transmit a telemetry signal indicative of the condition of the turbine blade, and a stationary antenna (144) may be affixed to a stationary component to receive the telemetry signal indicative of the condition of the turbine blade. The WBIC is effective for reduction in the footprint and component count compared to telemetry systems involving a discrete circuit implementation.

Description

WIDE-BANDGAP INTEGRATED CIRCUITRY FOR WIRELESS TELEMETRY IN A HIGH-TEMPERATURE ENVIRONMENT OF TURBOMACHINERY [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 [0005] Disclosed embodiments are generally related to wireless telemetry in a high-temperature environment of turbomachinery, such as a gas turbine engine, and, more particularly, to wide-bandgap integrated circuitry for a wireless telemetry system in the high-temperature environment of the gas turbine engine. [0006] 2. Description of the Related Art [0007] Turbomachinery, 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 demands for higher combustion efficiency. [0008] It is desirable to use a wireless telemetry system, which may be used to monitor operational parameters of the engine, such as monitoring operating

temperature of rotating components of the turbine, e.g., a turbine blade, or monitoring thermo-mechanical stresses placed upon such components during operation of the engine. [0009] Disclosed embodiments offer improvements in connection with a wireless telemetry system operating in the high-temperature, high g-force environment of the gas turbine engine. See US patent 8,803,703 for one example of circuitry that may be configured to operate in the high-temperature, high g-force environment of the engine. [0010] BRIEF DESCRIPTION [0011] One disclosed embodiment is directed to a wireless telemetry system to operate in a high-temperature environment of a gas turbine engine. The telemetry system may include a sensor on a turbine blade. A wide-bandgap integrated circuitry including a telemetry transmitter circuitry is connected to receive a sensor signal from the sensor indicative of a condition of the turbine blade or other rotating machinery. The wide-bandgap integrated circuitry may further include power-conditioning circuitry to condition power in a power transfer system for energizing the telemetry transmitter circuitry located on the turbine blade. A non-stationary antenna may be affixed to the turbine blade. The telemetry transmitter circuitry is connected to the non-stationary antenna to transmit a telemetry signal indicative of the condition of the turbine blade, and a stationary antenna may be affixed to a stationary component proximate to the non-stationary antenna to receive the telemetry signal indicative of the condition of the turbine blade. [0012] In accordance with a further disclosed embodiment, an integrated circuitry is configured to operate in a high-temperature environment of a gas turbine engine. The integrated circuitry includes a telemetry transmitter circuitry located on a turbine blade and connected to receive a sensor signal from a sensor on the blade indicative of a condition of the turbine blade. The integrated circuitry further includes a power- conditioning circuitry to condition power in a power transfer system for energizing the telemetry transmitter circuitry located on the turbine blade. The integrated circuitry comprises a wide-bandgap integrated circuitry. [0013] BRIEF DESCRIPTION OF THE DRAWINGS [0014] FIG.1 is a cross sectional view of one non-limiting example of a gas 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 wide-bandgap integrated circuitry. [0016] FIG.3 is a block diagram of a wide-bandgap integrated circuitry for a disclosed wireless telemetry system that may include power-conditioning circuitry and telemetry transmitter circuitry.

[0017] FIG.4 is a block diagram illustrating non-limiting details of a disclosed telemetry transmitter circuitry. [0018] FIG. 5 is a circuit diagram of one non-limiting embodiment of a disclosed telemetry transmitter circuitry. [0019] DETAILED DESCRIPTION [0020] The inventors of the present invention have recognized that a practical limitation of certain known wireless telemetry systems designed for operating in the high-temperature, high g-force environment of turbomachinery, such as a gas turbine engine, is the difficulty of making integrated circuitry that cost-effectively and reliably makes use of integrated wide-bandgap semiconductor technology to perform sensor data collection and wireless data transmission. [0021] In view of such recognition, the present inventors propose an innovative wireless telemetry system that makes use of integrated wide-bandgap semiconductor technology capable of cost-effective, accurate and reliable sensor data collection and wireless data transmission 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).

[0022] Disclosed embodiments of wide-bandgap integrated circuitry are conducive to a wireless telemetry system, which is substantially thermo-mechanically stable and compact. That is, disclosed embodiments of wide-bandgap integrated circuitry are conducive to substantial reduction in the wireless telemetry system footprint and component count compared to telemetry systems involving a discrete circuit implementation. This reduced footprint and component count in turn is conducive to a substantial increase in reliability due to wiring and/or packaging simplicity, and an overall reduction in mass due to the smaller footprint of the disclosed wireless telemetry system. Additionally, the robust circuit integration that can be realized in a disclosed wide-bandgap integrated circuitry is further effective to yielding a substantially reduced variation in signal measurement and signal conditioning.

Another benefit is reduction of circuitry matching efforts, as the integrated circuitry is expected to be locally matched, providing improved performance in comparison to a discrete circuit implementation. [0023] 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. [0024] 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. [0025] 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. [0026] FIG.1 illustrates a non-limiting example of turbomachinery 10, such as a gas turbine engine, as may be used for generating electricity. Disclosed embodiments may be used in a gas turbine engine 10 or in numerous other operating environments and for various purposes, such as for aerospace applications. [0027] Gas 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 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. Without limitation, 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. [0028] 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. One or more sensors 102 may be disposed on a movable component 104 of the turbine engine (e.g., a non-stationary turbine blade). A telemetry transmitter circuitry 106 may be connected to sensor 102 to receive from sensor 102 a sensed signal, such as a signal indicative of a condition of movable component 104. This signal may be appropriately conditioned and processed in telemetry transmitter circuitry 106, as described in greater detail below, and then transmitted to a non-stationary antenna 142 on movable component 104. [0029] A wireless power-transfer system 108 may be arranged to wirelessly supply electrical power to circuitry on the movable component, e.g., telemetry transmitter circuitry 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. [0030] 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. [0031] In operation, air is drawn in through compressor 12 (FIG. 1), where it is compressed and conveyed to combustor 14. Combustor 14 mixes the air with fuel and ignites it thereby forming a working gas. Without limitation, 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. Gas turbine engine 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. [0032] 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 gas turbine engine 10. [0033] FIG.3 is a block diagram of a wide-bandgap integrated circuitry 98 for a disclosed wireless telemetry system 100. FIG.3 illustrates respective non-limiting embodiments of wireless power-transfer system 108 and telemetry transmitter circuitry 106. In one non-limiting embodiment, wide-bandgap integrated circuitry 98 may be constructed as an application specific integrated circuitry (ASIC), e.g., without limitation an analogue ASIC. In one non-limiting embodiment, disclosed wireless telemetry system 100 may be constructed with integrated, wide-bandgap complimentary metal-oxide-semiconductor (CMOS) transistor technology. As would be appreciated by those skilled in the art, for example, wide-bandgap CMOS circuitry offers greater circuitry functionality with lower power dissipation than is currently possible with wide-bandgap junction gate field-effect transistor (JFET) technology. [0034] As would be further appreciated by those skilled in the art, wide-bandgap materials are typically compound semiconductors such as gallium nitride (GaN), aluminum gallium nitride (AlGaN), indium gallium nitride (InGaN), or silicon carbide (SiC). A notable wide-bandgap material that is not a compound semiconductor is carbon (C) in one of its covalent bonded forms, diamond. These materials usually have a bandgap greater than 2 electron volts (eV), compared with silicon and other common materials that have a bandgap on the order of 1 to 1.5 (eV). [0035] In one non-limiting embodiment, the wide-bandgap integrated circuitry may comprise a wide-bandgap semiconductor material, such as without limitation SiC, GaN, AlN, CaN, AlGaN, GaAs, GaP, InP, AlGaAs, AlGaP, AlInGaP, GaAsAlN, and diamond. That is, although SiC-based and III-nitride (III-N)-based devices (e.g., primarily GaN) may currently be the most widely developed wide-bandgap

semiconductors, disclosed embodiments do not preclude utilization of other wide- bandgap semiconductor materials. In one non-limiting embodiment, the wide bandgap integrated circuitry may be configured to operate in a temperature range from 200°C to 600°C. In another non-limiting embodiment, the wide bandgap integrated circuitry may be configured to operate in a temperature range from 300°C to 550°C. In yet another non-limiting embodiment, the wide bandgap integrated circuitry may be configured to operate in a temperature range from 350°C to 500°C. [0037] In one non-limiting embodiment, wireless power-transfer system 108 may include power-conditioning circuitry 150, as may include a bandgap voltage reference 151 connected to compensate a voltage regulator 152 in power transfer system 108. In one non-limiting embodiment, voltage regulator 152 may be connected to receive a rectified and filtered DC signal respectively supplied by a bridge rectifier 154 and filter network 156. [0038] In one non-limiting embodiment, telemetry transmitter circuitry 106 may include a multi-channel signal conditioning circuitry 160 connected to a voltage controlled oscillator 162. One non-limiting embodiment of multi-channel signal conditioning circuitry 160 is illustrated in FIG. 4. [0039] For the sake of simplicity of illustration, FIG.4 shows a multi-channel signal conditioning circuitry 160 made up of two signal-conditioning channels. It will be appreciated that this number of signal-conditioning channels should be construed in an example sense and not in a limiting sense. The description below is provided with an expectation of gaining a practical insight in connection with the multi- functional versatility that can be realized with a disclosed wide-bandgap integrated circuitry, as may be used in the high-temperature environment of a gas turbine engine. [0040] In one non-limiting embodiment, each respective signal-conditioning channel may include a differential amplifier 162 coupled to receive a sensor signal from 163 a respective sensor 102. The sensor signal may be a voltage differential indicative of the condition of the turbine blade. In one non-limiting embodiment, a chopper circuitry 164 may be coupled to receive an output 165 from differential amplifier 162 and configured to supply an output signal comprising an alternating current (AC) signal 166, which alternates in correspondence with a frequency signal 167 from a subcarrier oscillator 168. [0041] In one non-limiting embodiment, a frequency division multiplexer 170 may be coupled to receive the output signal from the respective chopper circuitry in each respective signal-conditioning channel. In one non-limiting embodiment, voltage controlled oscillator 169 (FIG.3) may have an input coupled to an output of frequency division multiplexer 170 for generating the telemetry signal, which comprises an oscillatory signal having a frequency indicative of the sensed condition of the turbine blade. Voltage controlled oscillator 169 may have an output coupled to non-stationary antenna 142 for transmitting the oscillatory signal having the frequency indicative of the sensed condition of the turbine blade. In one non-limiting embodiment, frequency division multiplexer 170 is responsive to a temperature- dependent variable frequency oscillator 172. [0042] FIG. 5 is circuit diagram of one non-limiting embodiment of a disclosed telemetry transmitter circuitry mapped in correspondence with the multi-functional functionality described in the context of FIG.4, which will not be redone here for the sake of avoiding pedantic and burdensome repetition. [0043] In operation, disclosed embodiments provide in a cost-effective manner, a robust, wireless telemetry system that makes use of integrated wide-bandgap semiconductor technology to perform efficient, accurate and reliable sensor data collection and wireless data transmission while subject to the high-temperature environment of a gas turbine engine. Disclosed embodiments are effective for implementing a simpler, yet robust wireless telemetry architecture conducive to uncomplicated installation and efficient operation of a wireless telemetry 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. [0044] 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. A wireless telemetry system (100) for use in a gas turbine engine, the wireless telemetry system comprising:

a sensor (102) on a turbine blade;

a wide-bandgap integrated circuitry (98) comprising a telemetry transmitter circuitry (106) connected to receive a sensor signal from the sensor indicative of a condition of the turbine blade;

the wide-bandgap integrated circuitry further comprising power-conditioning circuitry (150) to condition power in a wireless power transfer system (108) for energizing the telemetry transmitter circuitry located on the turbine blade;

a non-stationary antenna (142) affixed to the turbine blade, wherein the telemetry transmitter circuitry is connected to the non-stationary antenna to transmit a telemetry data signal indicative of the condition of the turbine blade; and

a stationary antenna (144) affixed to a stationary component (112) proximate to the non-stationary antenna receive the telemetry data signal indicative of the condition of the turbine blade.

2. The wireless telemetry system of claim 1, wherein the telemetry transmitter circuitry comprises integrated, complimentary metal-oxide-semiconductor (CMOS) SiC transistor circuitry.

3. The wireless telemetry system of claim 1, wherein the wide-bandgap integrated circuitry comprises an analogue, application specific integrated circuitry (ASIC).

4. The wireless telemetry system of claim 1, wherein the wide-bandgap integrated circuitry is configured to operate in a temperature range from 200°C to 600°C.

5. The wireless telemetry system of claim 4, wherein the wide-bandgap integrated circuitry is configured to operate in a temperature range from 300°C to 550°C.

6. The wireless telemetry system of claim 5, wherein the wide-bandgap integrated circuitry is configured to operate in a temperature range from 350°C to 500°C.

7. The wireless telemetry system of claim 1, wherein the wide-bandgap integrated circuitry comprises a semiconductor material selected from the group consisting of SiC, GaN, AlN, CaN, AlGaN, GaAs, GaP, InP, AlGaAs, AlGaP, AlInGaP, GaAsAlN, and diamond.

8. The wireless telemetry system of claim 1, wherein the power-conditioning circuitry comprises a bandgap voltage reference (151) connected to compensate a voltage regulator (152) in the power transfer system.

9. The wireless telemetry system of claim 1, wherein the telemetry transmitter circuitry comprises a multi-channel signal-conditioning circuitry (160).

10. The wireless telemetry system of claim 9, wherein the multi-channel signal- conditioning circuitry comprises:

a differential amplifier (162) coupled to receive the sensor signal from the sensor, the sensor signal comprising a voltage differential indicative of the condition of the turbine blade;

chopper circuitry (164) coupled to receive an output from the differential amplifier and configured to supply an output signal comprising an alternating current (AC) signal, which alternates in correspondence with a frequency signal from a subcarrier oscillator;

a frequency division multiplexer (170) coupled to receive the output signal from the chopper circuitry; and

a voltage controlled oscillator (169) having an input coupled to an output of the frequency division multiplexer for generating the telemetry signal, which comprises an oscillatory signal having a frequency indicative of the sensed condition of the turbine blade, the voltage controlled oscillator having an output coupled to the non-stationary antenna for transmitting the oscillatory signal having the frequency indicative of the sensed condition of the turbine blade.

11. An integrated circuitry (98) to operate in a high-temperature environment of a gas turbine engine, comprising:

a telemetry transmitter circuitry (106) located on a turbine blade and connected to receive a sensor signal from a sensor (102) on the blade indicative of a condition of the turbine blade;

the integrated circuitry further comprising a power-conditioning circuitry (150) to condition power in a power transfer system (108) for energizing the telemetry transmitter circuitry located on the turbine blade,

wherein the integrated circuitry comprises a wide-bandgap integrated circuitry.

12. The integrated circuitry of claim 11, wherein the telemetry transmitter circuitry comprises integrated, complimentary metal-oxide-semiconductor (CMOS) SiC transistor circuitry.

13. The integrated circuitry of claim 11, wherein the wide-bandgap integrated circuitry comprises an analogue, application specific integrated circuitry (ASIC).

14. The integrated circuitry of claim 11, wherein the wide-bandgap integrated circuitry is configured to operate in a temperature range from 200°C to 600°C.

15. The integrated circuitry of claim 14, wherein the wide-bandgap integrated circuitry is configured to operate in a temperature range from 300°C to 550°C.

16. The integrated circuitry of claim 15, wherein the wide-bandgap integrated circuitry is configured to operate in a temperature range from 350°C to 500°C.

17. The integrated circuitry of claim 11, wherein the wide-bandgap integrated circuitry comprises a semiconductor material selected from the group consisting of SiC, GaN, AlN, CaN, AlGaN, GaAs, GaP, InP, AlGaAs, AlGaP, AlInGaP, GaAsAlN, and diamond.

18. The integrated circuitry of claim 11, wherein the power-conditioning circuitry comprises a bandgap voltage reference (151) connected to compensate a voltage regulator (152) in the power transfer system.

19. The telemetry system of claim 11, wherein the telemetry transmitter circuitry comprises a multi-channel signal-conditioning circuitry (160) comprising:

a frequency division multiplexer (17) coupled to receive the output signal from the chopper circuitry; and

a voltage controlled oscillator (169) having an input coupled to an output of the frequency division multiplexer for generating the telemetry signal, which comprises an oscillatory signal having a frequency indicative of the sensed condition of the turbine blade, the voltage controlled oscillator having an output coupled to a non-stationary antenna for transmitting the oscillatory signal having the frequency indicative of the sensed condition of the turbine blade.