Air Cycle Machine Compressor Housing Stress Management
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Solution Overview
Problem
Air cycle machine compressors face high stress due to increased loads, which existing housings fail to adequately address without compromising the weight of the compressor.
Innovation Solution
The housing design features specific wall thickness ratios and fillet radii configurations, such as a first angle with a 1.565 ratio and a first fillet radius with a 4:1 ratio compared to the general dimensions, to distribute stress effectively while minimizing weight impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the housing wall thickness is increased to handle high stress, then the strength and reliability are improved, but the weight of the compressor increases
Solution Approach 1:
The housing employs varying wall thicknesses in different regions - thicker walls (1.565 times general thickness) at high-stress areas such as the first angle regions, and standard thickness elsewhere. This localized reinforcement approach provides the necessary strength where needed while avoiding unnecessary weight increases in low-stress areas.
Solution Approach 2:
The patent applies specific parameter ratios to the housing design - a first wall thickness ratio of 1.565 and a first fillet radius ratio of 4.0 compared to general wall thickness and fillet radius respectively. These optimized parameters balance structural requirements with weight minimization.
2Reliability
If the wall thickness ratio is increased to 1.565 to manage high stress, then the structural integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
The housing is divided into distinct regions with different wall thickness characteristics - areas with the first angle having increased thickness (1.565 ratio) and areas with general wall thickness. This segmentation allows each region to be optimized for its specific functional requirements while maintaining overall manufacturability through standardized manufacturing processes.
3Strength
If the fillet radius ratio is increased to 4.0 to distribute stress, then the stress distribution is improved, but the material usage increases
Solution Approach 1:
The housing features localized fillet radius variations - a first fillet radius with a 4.0 ratio compared to general fillet radius - positioned specifically where stress concentration occurs. This localized approach improves stress distribution at critical locations without requiring increased material usage throughout the entire housing structure.
Data Source
AI summary
A housing of an air cycle machine compressor is provided. The housing includes a body defining an aperture therethrough and one or more bosses located circumferentially around the body, the body having a general wall thickness. A duct is configured on a portion of the body. The body includes a first angle defining an area extending over a circumferential direction of the body having a first wall thickness different from the general wall thickness. The first angle is configured with the first wall thickness having a ratio of 1.565 as compared to the general wall thickness.