Alignment Tool for Air Cycle Machine Diffuser Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for aligning static parts in air cycle machines, such as pinning or precision manufacturing, add complexity and cost to the assembly process, and can lead to misalignment issues that cause wear between rotating and static parts.
Innovation Solution
An alignment tool with specific annular surfaces is used to precisely align the diffuser and seal plate within the air cycle machine, eliminating the need for pinning and allowing for less stringent manufacturing tolerances, thereby simplifying and cost-reducing the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pinning process is used to align static parts, then alignment accuracy is improved, but device complexity increases due to additional components and assembly steps
Solution Approach 1:
The alignment tool is designed with pre-configured annular surfaces at specific diameters that correspond to the seal plate and diffuser flange dimensions. These surfaces are prepared in advance to provide automatic alignment when the tool is installed on the shaft, eliminating the need for complex pinning procedures during assembly.
Solution Approach 2:
The alignment tool serves as an intermediary device between the shaft and the static parts (seal plate and diffuser). It provides a mediating mechanism with annular surfaces that facilitate precise alignment without requiring direct complex interactions between the components themselves, thereby simplifying the overall assembly process.
2Manufacturing precision
If precision manufacturing is used to ensure perfect alignment, then alignment accuracy is improved, but manufacturing cost and time increase
Solution Approach 1:
The alignment tool utilizes parameter changes in the form of annular surfaces with specific diameters that match the seal plate and diffuser flange dimensions. By varying the diameter parameter of these annular surfaces, the tool provides precise alignment for different components without requiring each component to be manufactured with high precision, thereby reducing manufacturing costs and time.
3Reliability
If journal bearings are closely aligned, then reliability is improved by preventing rubbing and wear, but assembly complexity increases
Solution Approach 1:
The alignment tool provides preliminary alignment action for the journal bearings through its annular surfaces that contact the seal plate and diffuser. This preliminary alignment ensures that when the static parts are assembled, the journal bearings are automatically positioned correctly, preventing future rubbing and wear without requiring complex alignment procedures.
Data Source
AI summary
A method of installing a diffuser in an air cycle machine includes placing a first housing on a shaft, placing a seal plate on the shaft, and placing a diffuser on the shaft. Next, the diffuser and the seal plate are aligned with an alignment tool. The alignment tool has a first annular surface to align with a radially outer surface of the seal plate and a second annular surface to align with an annular flange on the diffuser. Finally, the diffuser is fastened to the seal plate and the alignment tool is removed from the diffuser and the seal plate.