Composite material wheel blades for aircraft turbine engines

Abstract

A fan blade (1) for an aircraft turbine engine, the blade comprising a blade (13) connected to a root (11), the blade being made of a composite material based on woven fibers and embedded in a polymer resin, the blade also comprising a medium (2) for identifying the blade, the medium being a radio identification medium, characterized in that the fan blade comprises at least one first portion (30, 32) and at least one second portion (34), the fibers of the first portion being only conductive fibers, the fibers of the second portion being formed of a mixture of conductive and non-conductive fibers, and the identification medium being located in or on the second portion (34).

Description

Technical Field

[0001] This invention relates to composite material blades for aircraft turbine engines and methods for manufacturing such composite material blades. Background Technology

[0002] Prior art specifically includes documents EP-3 211 366, EP-3 093 800 and US-2009 / 188324.

[0003] In a known manner, refer to Figure 1 The diagram illustrates a turbine engine 100 extending along a turbine engine axis X, enabling an aircraft to move via an airflow entering the turbine engine 100 and flowing from upstream to downstream. In the following text, the terms "upstream" and "downstream" are defined relative to the turbine engine axis X, which is oriented from upstream to downstream. Similarly, the terms "inner" and "outer" are defined along a radial direction R defined relative to the axis X.

[0004] In a known manner, the turbine engine 100 includes a compressor, a combustion chamber, and a turbine for driving the compressor to rotate. The turbine engine 100 includes an upstream fan 110 that accelerates the upstream-to-downstream airflow in the turbine engine 100.

[0005] The fan 110 includes a disc 111 rotatably fixed to the compressor shaft. The disc includes receptacles distributed around the outer periphery of the disc 111. Blades 1 are respectively mounted in the receptacles from upstream to downstream along the turbine engine axis X via axial insertion portions. The blades 1 extend in the same plane transverse to the turbine engine axis X. In this example, the turbine engine 100 includes a tapered portion 112 mounted upstream of the disc 111.

[0006] Preferably, refer to Figure 2 Each blade 1 extends radially along axis R relative to the turbine engine axis X and successively includes: a radially inner mounting root 11 configured to be mounted in one of the receptacles of the disk 111; a radially outer air deflector blade 13; a radially outer surface; and possibly a platform 12 for connecting the root 11 to the blade 13. Alternatively, the platform 12 may be detachable from the blade 1 and mounted on the disk 111 independently of the mounting of the blade on the disk.

[0007] In a known manner, each fan blade 1 is uniquely identified by a serial number (SN) and a part number (PN). (See reference...) Figure 2 and Figure 3The serial number 21 and version number 22 are written on the medium 2, preferably on the fabric, which is attached to a portion of the root 11 and covered with a protective coating.

[0008] In practice, the fan 110 of the turbine engine 100 must be equipped with sufficient fan blades 1 for the turbine engine 100 to operate optimally. In particular, it must be ensured that the fan blades 1 of the same fan 110 have compatible serial numbers 21 and version numbers 22.

[0009] This presents a problem for companies leasing turbine engines to customers, as customers may need to replace one or more blades 1 of the fan 110 during the rental period. Upon return of the turbine engine, the lessor is responsible for verifying that the blades 1 installed in the fan 110 are compatible before the turbine engine can be leased again.

[0010] Inspecting the serial number 21 and version number 22 of the fan blade 1 is particularly tedious and time-consuming. In order to visually access the medium 2, which includes serial number 21 and version number 22, the operator must disassemble the upstream part of the turbine engine before approaching the blade 1, in particular disassembling the fan cone 112, housing, lock, and gasket.

[0011] After reading serial number 21 and version number 22, the operator must reassemble the upstream section of the turbine engine, which is time-consuming and increases the risk of damage and assembly errors (non-conformance). Furthermore, this method does not prevent the operator from mistakenly entering serial number 21 and version number 23.

[0012] Incidentally, in another application, prior art known through patent application EP-A1-2 224 379, the use of radio-identification (RFID) media on compressor blades to track the state of the compressor blades during the operation of a turboshaft engine is described. For this purpose, an RFID reader is provided in the turboshaft engine to read the RFID media over time. This teaching is independent of the operator attempting to identify the blades from outside the turboshaft engine. This is because the turboshaft engine has many metal components that provide electromagnetic shielding and form a Faraday cage.

[0013] The applicant has proposed a solution to this problem by using fan blades equipped with radio identification media, which is glued to the root of the blades.

[0014] This invention proposes an improvement to the technology, which specifically optimizes the detection of the identification medium of the impeller blades. Summary of the Invention

[0015] This invention relates to a fan blade for an aircraft turbine engine. The blade includes blades connected to a root and is made of a composite material based on woven fibers embedded in a polymer resin. The blade also includes a medium for identifying the blade, the medium being a radio identification medium. The fan blade is characterized by comprising at least one first portion and at least one second portion, the first portion being composed of only conductive fibers, the second portion being formed of a mixture of conductive and non-conductive fibers, and the identification medium being located in or on the second portion.

[0016] Commercial radio frequency identification (RFID) type identification media come in a variety of designs. RFID type identification media are easy and inexpensive to procure, but the performance of the identification chain depends heavily on the environment in which the media is deployed and how the media is designed.

[0017] There are two known types of RFID media:

[0018] - The so-called "metallic" dielectric must be at least 1.5 mm thick to operate at high or ultra-high frequency (UHF) frequencies.

[0019] - "Non-metallic" or non-conductive medium, with a thickness of less than 0.5 mm, for use in UHF applications.

[0020] Because of the small thickness of non-metallic RFID media, and because the application of non-metallic RFID media is of particular interest to blades with a thin thickness imposed by aerodynamic constraints, it should be understood that non-metallic RFID media are advantageous.

[0021] A crucial feature for maximizing the detection distance of a medium using a suitable reading device is that the medium is arranged within an electrically insulating medium. However, the proximity of conductive elements can interfere with the operation of the medium. The organic resin used to manufacture fan blades is inherently insulating, while the carbon in the woven fibers of the preforms used for the fan blades is a good electrical conductor.

[0022] Positioning the identification medium in areas rich in non-conductive fibers reduces dissipation caused by conductive carbon fibers and increases the detection distance from a few centimeters (10cm to 20cm) to several meters (2m to 10m). Furthermore, to ensure the medium does not adversely affect the mechanical properties of the composite material, the choice of model and the location of the medium within the impeller are preferably carefully defined. The identification medium is integrated into the impeller, thus protecting it from external environmental influences.

[0023] This solution also enables the medium to be positioned as far away as possible from the fan cone of the engine (which is another interfering element for RFID signals) without affecting the aerodynamic surface of the blades.

[0024] The blades according to the invention may include one or more of the following features, which may be considered individually or in combination with each other:

[0025] The identification medium comprises a spherical portion and a metal radio antenna, the spherical portion being located within the space between the woven fibers; the identification medium is then completely contained within the resin bag portion, thus ensuring that the medium does not affect the integrity of the impeller.

[0026] - The spherical part is non-metallic, for example, a polymer.

[0027] - The antenna is planar.

[0028] - The spherical part is completely embedded in the polymer resin.

[0029] - The diameter of the spherical part is less than or equal to 5 mm, and the thickness of the antenna is less than or equal to 0.5 mm.

[0030] - Conductive fibers are carbon fibers, while non-conductive fibers are glass fibers or thermoplastic fibers, such as those selected from aramid, polyethylene, and polyester fibers.

[0031] - The second part extends along the trailing edge of the blade.

[0032] - The resin of the impeller is a thermosetting resin or a thermoplastic resin.

[0033] - The resin for the impeller blades is epoxy resin or bismaleimide resin.

[0034] - The identification medium is configured to operate at frequencies between 860MHz and 930MHz.

[0035] The present invention also relates to an aircraft turbine engine comprising a fan, the fan comprising a disc supporting fan blades, at least one of such fan blades being as described above.

[0036] The present invention also relates to a method for manufacturing the impeller as described above, wherein the method includes the following steps:

[0037] a) Inserting at least one preform made of woven fibers and an identification medium into a mold, said at least one preform being made of conductive and non-conductive fibers, the identification medium being located in a region of the preform including non-conductive fibers, and

[0038] b) Inject resin into the mold to simultaneously embed the preform and the identification medium. Attached Figure Description

[0039] Other features and advantages of the invention will become apparent from the following detailed description, and with reference to the accompanying drawings, in order to understand it:

[0040] [ Figure 1 ] Figure 1 This is a schematic diagram of the longitudinal section of a turbine engine based on existing technology;

[0041] [ Figure 2 ] Figure 2 This is a schematic diagram of a fan blade with a media identification feature, based on existing technology;

[0042] [ Figure 3 ] Figure 3 yes Figure 2 A schematic diagram of the identification medium;

[0043] [ Figure 4 ] Figure 4 This is a schematic diagram illustrating the steps for reading RFID type identification media from the fan blades of a turbine engine;

[0044] [ Figure 5 ] Figure 5 This is a schematic diagram of a fan blade with a medium identification feature according to the present invention;

[0045] [ Figure 6 ] Figure 6 This is a schematic diagram of the identification medium; and

[0046] [ Figure 7 ] Figure 7 This is a schematic diagram of a woven prefabricated component, in which the identification medium is located. Detailed Implementation

[0047] As described above Figures 1 to 3 .

[0048] Reference Figure 4 A turbine engine 100 is shown, extending along a turbine engine axis X and enabling an aircraft to move by an airflow entering the turbine engine 100 and flowing from upstream to downstream. Hereinafter, the terms "upstream" and "downstream" are defined relative to the turbine engine axis X, which is oriented from upstream to downstream. Similarly, the terms "inner" and "outer" are defined along a radial direction R defined relative to the axis X. In a known manner, the turbine engine 100 includes a compressor, a combustion chamber, and a turbine for driving the compressor to rotate. The turbine engine 100 includes an upstream fan 110 that accelerates the upstream-to-downstream airflow within the turbine engine 100.

[0049] The fan 110 includes a disc 111 rotatably fixed to the compressor shaft. The disc includes receptacles distributed around the outer periphery of the disc 111. Blades 1 are respectively mounted in the receptacles from upstream to downstream along the turbine engine axis X via axial insertion portions. The blades 1 extend in the same plane transverse to the turbine engine axis X. For clarity and simplicity, only one blade 1 will be shown from now on. In this example, the turbine engine 100 has a tapered portion 112 mounted upstream of the disc 111.

[0050] Each blade 1 extends along a radial axis R and successively includes: a mounting root 11 configured to be axially mounted in a housing of a disk 111 of the fan 110 along the turbine engine axis X; an air deflector blade 13 extending radially relative to the turbine engine axis X along the radial axis R; and an optional platform 12 for connecting the blade 13 to the root 11. The blade 1 extends radially in the mounting position. Therefore, the mounting root 11 is described as radially inward, while the air deflector blade 13 is described as radially outward.

[0051] The impeller 1 is made of a composite material comprising various fibers embedded in a polymeric resin. According to the invention, some fibers are conductive (and are referred to as conductive fibers), while others are non-conductive (and are referred to as non-conductive fibers). The polymeric resin is non-conductive.

[0052] The conductive fiber is preferably a metal fiber, and particularly a carbon fiber.

[0053] The non-conductive fiber is preferably glass fiber or thermoplastic fiber (aramid, polyethylene, polyester, etc.).

[0054] The fibers are woven together to form at least one preform intended to be embedded in the resin.

[0055] In this example, the resin is thermosetting, but resins can have different properties. The resin can be an epoxy resin or a bismaleimide resin.

[0056] Figure 5 An example of a fan blade 1 according to a preferred embodiment of the present invention is shown.

[0057] As described above, the impeller 1 includes a root 11 and a blade 13. The root 11 of the impeller 1 is formed here by a preform or a portion 30 composed of preforms, which consists only of woven carbon fibers. The same is true for the main components of the blade 13, particularly the leading edge 1b of the blade, which is made of a preform or a portion 32 composed of preforms, which therefore consists only of carbon fibers. The preform is typically single and extends into both portions 30, 32.

[0058] Conversely, the portion of the blade 13 extending along the trailing edge 1a is made by weaving carbon fibers and glass fibers, thus this portion includes a preform or a portion 34 composed of a preform made of a composite material.

[0059] exist Figure 5 In the middle, part 30-34 is defined by a rectangle marked with a dashed line.

[0060] According to the invention, preferably, the RFID-type identification medium 2 is located in portion 34, and thus, in the example shown, near the trailing edge 1a of the impeller. This is particularly advantageous because it facilitates detection of the medium 2 from a distance by the reading device 4, as in... Figure 4 As shown in the figure. Preferably, the identification medium 2 is configured to be detected and operated at a frequency between 860MHz and 930MHz.

[0061] Figure 6 A preferred example of the identification medium 2 used in this invention is shown.

[0062] The identification medium 2 includes a spherical portion 40 associated with a metallic radio antenna 42 (e.g., a planar metallic radio antenna). The largest element in volume of the medium 2 is the spherical portion 40, preferably with a diameter of 5 mm or less. The antenna 42 is planar and may extend parallel to the surface of the blade 13 or the wheel blade 1, or may extend between two fiber layers or two fiber webs of the preform. The thickness of the antenna 42 is, for example, less than or equal to 0.5 mm.

[0063] This type of medium 2 has the advantages of meeting the requirements for size, thermal stability, and chemical compatibility in the field. Furthermore, preferably, the material of the medium is selected as:

[0064] -Does not affect the resin or its polymerization.

[0065] - It is thermally stable during the possible curing of the resin-impregnated preform or during the exothermic polymerization reaction of the resin.

[0066] - The manufacturing mold for the impeller is closed without interfering with the weaving and prefabrication, and

[0067] - The size is not very large.

[0068] The spherical part 40 is made of a polymer, for example, and the antenna 42 is made of copper or aluminum, for example, and is covered with a thermoplastic polymer or epoxy polymer (PET, PC, etc.).

[0069] The identification medium 2 has a memory within the spherical portion 40, where identification and characterization data can be stored. This identification and characterization data includes, for example, a serial number (ID1) referred to as the "serial number SN" and a version number (ID2) referred to as the "part number PN". It goes without saying that the memory 40 can store a single data item or a set of data items, such as a unique identifier that enables the part to be identified in a specific manner, or more than two identification data items, such as the manufacturer's identifier (CAGE code, etc.), manufacturing date, sensitivity to a specific fluid, operating authorization catalog, data related to the part's maintenance or logistical operations (such as the part's operating status), performed operations, etc. The antenna 42 of the identification medium 2 is configured to receive a read request REQ and send back the identification data ID1, ID2. The identification medium 2 may include a battery or be remotely powered. This type of identification medium 2 is well known to those skilled in the art.

[0070] In a known manner, identification media of the radio identification type are distinguished between identification media for "non-metallic" purposes, identification media for "metallic" purposes, and identification media for "mixed" purposes. Preferably, identification media 2 is used for "non-metallic" purposes.

[0071] According to the invention, antenna 42 includes at least one communication lobe L1 oriented along the radio axis XR, which is used to receive read requests REQ and send back identification data ID1, ID2. (As in...) Figure 6 As shown, antenna 42 may specifically include two communication lobes L1 aligned along the same radio axis XR. Therefore, this identification medium 2 can be used in two opposite directions along the same axis.

[0072] Figure 7 A portion of a woven preform of the impeller 1 according to the invention is shown, and a space E is shown in the preform to accommodate a metal spherical portion 40 for identifying the medium 2. These spaces E are located between the woven fibers, and it should be understood that the spherical portion 40 accommodated in one of these spaces is intended to be embedded in the polymeric resin impregnating the preform, and thus completely embedded in the polymeric resin.

[0073] The present invention also provides a method for manufacturing the impeller 1 as described above, wherein the method includes the following steps:

[0074] a) Inserting at least one preform made of woven fibers and an identification medium into a mold, the preform being made of conductive and non-conductive fibers, the identification medium being located in a region of the preform including the non-conductive fibers, and

[0075] b) Inject resin into the mold to simultaneously embed the preform and the identification medium.

[0076] Reference Figure 4 Methods for individually and collectively reading identification data ID1, ID2 of the blades 1 of the fan 110 of a turbine engine 100 (particularly an aircraft turbine shaft engine) will now be shown.

[0077] In this example, operator P uses a radio-identified reading device 4, which is known to those skilled in the art, and positions himself at a distance from the turbine engine 100, specifically upstream of the turbine engine to be close to the fan 110.

[0078] Using the radio-identified reading device 4, operator P sends a reading request REQ via radio, which is received by the antenna 42 of the identification medium 2 via radio.

[0079] In response to a read request REQ, antenna 42 of identification medium 2 transmits identification data ID1 and ID2 via radio, which are then read by a radio-identified reading device. Specifically, identification data ID1 and ID2 are transmitted via the communication lobe L1 of the antenna. The read identification data ID1 and ID2 are stored in a computerized manner in the radio-identified reading device 4.

[0080] With this invention, operator P can conveniently, quickly, and without error risk obtain the identification data ID1 and ID2 of the turbine blade 1. Furthermore, it eliminates the need for disassembly of the upstream portion of the turbine engine 100, as is done in the prior art.

[0081] Depending on the transmission power of the radio identification reading device 4 and the distance between the radio identification reading device 4 and the identification medium 2, the operator can read one identification medium 2 of the fan 100 blade 1 individually (low power and short distance), or read multiple identification media 2 of the fan 100 blade 1 collectively (high power and long distance). In practice, reading can be performed at a distance greater than 1m or 2m.

[0082] This invention has several advantages, including:

[0083] -Because the identification medium is integrated during the manufacturing of the blades, before the resin is injected into the manufacturing mold of the blades, there is no additional specific step for installing the identification medium 2;

[0084] - The identification medium 2 is integrated into the impeller, so the identification medium is tamper-proof; the identification medium cannot be removed without the risk of damaging the impeller 1.

[0085] - Medium 2 is embedded in polymer resin, therefore there is no risk of it falling off or being accidentally lost during operation; and

[0086] - Inspect medium 2 without removing the engine or impeller;

[0087] - Antenna 42 for identifying the medium also has the following advantages:

[0088] Compared to typically thicker and larger metal antennas, the antenna for identifying the medium is thin and therefore easier to position and integrate; and

[0089] This facilitates detection via the reading device 4.

Claims

1. A fan blade (1) for an aircraft turbine engine, the fan blade comprising blades (13) connected to a root (11), the fan blade being made of a composite material based on woven fibers and embedded in a polymerized resin, the fan blade further comprising a medium (2) for identifying the fan blade, the medium being a radio identification medium, characterized in that, The fan blades include at least one first part (30, 32) and at least one second part (34), the fibers of the first part being only conductive fibers, the fibers of the second part being formed by a mixture of conductive and non-conductive fibers, and the radio identification medium being located in or on the second part (34).

2. The fan blade (1) according to claim 1, wherein, The radio identification medium (2) includes a spherical portion (40) and a metal radio antenna (42), the spherical portion being located in the space between the woven fibers.

3. The fan blade (1) according to claim 2, wherein, The spherical portion (40) is completely embedded in the polymerized resin.

4. The fan blade (1) according to claim 2 or 3, wherein, The diameter of the spherical part (40) is less than or equal to 5 mm, and the thickness of the metal radio antenna (42) is less than or equal to 0.5 mm.

5. The fan blade (1) according to any one of claims 1 to 3, wherein, The conductive fiber is carbon fiber, and the non-conductive fiber is glass fiber or thermoplastic fiber.

6. The fan blade (1) according to any one of claims 1 to 3, wherein, The second part (34) extends along the trailing edge (1a) of the blade (13).

7. The fan blade (1) according to any one of claims 1 to 3, wherein, The resin is a thermosetting resin or a thermoplastic resin.

8. The fan blade (1) according to any one of claims 1 to 3, wherein, The radio identification medium (2) is configured to operate at frequencies between 860 MHz and 930 MHz.

9. The fan blade (1) according to claim 5, wherein, The non-conductive fiber is selected from aromatic polyamide, polyethylene and polyester fiber.

10. An aircraft turbine engine (100) comprising a fan (110) including a disk (111) carrying fan blades (1), at least one of the fan blades being a fan blade according to any one of claims 1 to 9.

11. A method for manufacturing a fan blade (1) according to any one of claims 1 to 9, wherein, The method includes the following steps: a) Inserting at least one preform made of woven fibers and the radio identification medium (2) into a mold, the at least one preform being made of conductive and non-conductive fibers, the radio identification medium being located in a region of the preform including non-conductive fibers, and b) Inject resin into the mold to simultaneously embed the preform and the radio identification medium.

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