Additively Manufactured Gimbal Structure for Pressurized Pipe Joints
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Solution Overview
Problem
Existing gimbals for gas turbine aircraft engines are limited by traditional manufacturing methods that restrict size, design, and strength, requiring skilled welding and are unsuitable for carrying pressurized fluids due to insufficient structural integrity.
Innovation Solution
A gimbal design comprising a core portion and joint shield portion formed as a single unitary component through additive layer manufacturing, eliminating the need for welding and enhancing structural strength and flexibility, suitable for connecting pipes or ducts in gas turbine engines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional extrusion, rolling and forming processes with welding are used to manufacture gimbals, then the manufacturing process is well-established and can connect various components, but the gimbal strength is insufficient to contain pressurized liquids and welds are prone to failure
Solution Approach 1:
The patent merges multiple separate components (pins, devices, bellows, flanges) into a single integrated gimbal structure manufactured by additive layer manufacturing. This eliminates the need for welding multiple components together, thereby improving strength while maintaining manufacturability through advanced manufacturing processes.
Solution Approach 2:
The patent replaces the traditional mechanical welding process with additive layer manufacturing technology. This substitution eliminates welds entirely while producing complex three-dimensional gimbal structures that maintain or improve strength characteristics compared to traditionally manufactured gimbals.
2Reliability
If skilled welders are used to manufacture gimbals with multiple welds, then various components can be connected, but the risk of weld failure increases and maintenance costs rise
Solution Approach 1:
The patent extracts and eliminates the welding process entirely from the gimbal manufacturing sequence. By using additive layer manufacturing, the gimbal is produced as a single monolithic structure without requiring any welding operations, thereby eliminating weld failure risks and associated maintenance issues.
3Adaptability or versatility
If traditional manufacturing processes are used for gimbals, then the manufacturing method is established, but the size, design and strength of the gimbal are restricted
Solution Approach 1:
The patent changes the manufacturing parameter from traditional subtractive or formative processes to additive layer manufacturing. This parameter change enables the production of gimbals with complex geometries, optimized stress distributions, and customized sizes that cannot be achieved with conventional manufacturing methods, thereby improving design flexibility.
Data Source
AI summary
A gimbal for connecting pipes having a core portion and at least one joint shield portion that surrounds the core portion. The core portion, which has a core portion internal surface and a core portion external surface, has at least two pipe engaging portions that are separated by at least one flexible portion, which has a flexible portion internal surface and a flexible portion external surface, and a plurality of joint cover portions. Each joint cover portion extends from the core portion external surface of the core portion to provide a protective cover for the flexible portion external surface of at least one flexible portion of the core portion and is pivotably connected to a least one joint shield portion. The shield portion is configured to provide a protective shield for at least one flexible portion of the core portion.