Airfoil Array Assembly Fixture with Positioning Saddle
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Solution Overview
Problem
The assembly of turbomachine airfoil arrays, particularly stator vanes, is challenging due to the lack of fixed features or fasteners in existing designs, making it difficult to secure and replace vanes without interference, especially during repair, as the rubber potting method complicates alignment and loading of partial airfoil arrays.
Innovation Solution
A fixture with a positioning saddle system that aligns and secures replacement airfoils within a turbomachine airfoil array by defining specific planes with contact points, allowing for the application and curing of a curable material between the airfoil and fairings, while maintaining relative positions and accommodating existing airfoils without obstructing them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rubber potting method is used to secure stator vanes in airfoil arrays, then vanes can be held in position without fasteners, but alignment and replacement of vanes becomes difficult and time-consuming
Solution Approach 1:
The fixture divides the airfoil array into individual working positions, with each position equipped with separate positioning elements (saddles, blocks, pins) that can independently hold and position individual airfoils. This segmentation allows one airfoil to be replaced or serviced without affecting others, solving the difficulty of replacement in potted assemblies.
Solution Approach 2:
The fixture acts as an intermediary device between the airfoil array and the assembly/disassembly process. It provides temporary mechanical support and positioning during maintenance operations, eliminating the need to work directly with the potted vanes and making replacement straightforward.
2Manufacturing precision
If fixed features or fasteners are used to secure stator vanes, then alignment is easier, but the design becomes more complex and interference during assembly increases
Solution Approach 1:
The patent extracts the positioning function from the airfoil array design itself and places it in a separate fixture. The fixture contains all the positioning features (saddles, blocks, pins) needed for alignment, while the airfoils themselves remain simple without integrated fasteners or complex alignment features.
Solution Approach 2:
The fixture provides adjustable and reconfigurable positioning elements that can be moved, removed, or repositioned as needed. The positioning saddles can be selectively positioned at different circumferential locations, and fixtures can be reconfigured for different airfoil types, providing dynamic adaptability without permanent complex features.
3Ease of operation
If alignment features are present in the existing assembly, then positioning is easier, but loading a partial airfoil array becomes difficult
Solution Approach 1:
The fixture provides positioning features only at the specific working position where an airfoil is being replaced, while leaving other areas open and unobstructed. This allows partial airfoil arrays to be loaded without interference from alignment features, as those features are localized only to active work zones.
4Productivity
If a complete airfoil array is assembled at once, then production efficiency is higher, but difficulty of assembly increases due to interference between components
Solution Approach 1:
The fixture enables assembly of complete airfoil arrays by breaking down the process into independent, non-interfering working positions. Each position can be prepared and loaded separately, then assembled together without component interference, achieving both high productivity and ease of assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates efficient and precise assembly and replacement of airfoils by maintaining alignment and securing the airfoil array during curing, reducing interference and simplifying the repair process by providing unobstructed areas for existing airfoils, thus improving the overall assembly efficiency and reducing complexity.
Implementation Method 1
applying a curable material at an interface between the replacement airfoil and the inner and outer fairing, and curing the curable material while maintaining a relative position between the replacement airfoil and the inner and outer fairing
Data Source
AI summary
An example method of assembling a turbomachine airfoil array includes, among other things, securing a partial airfoil array within a fixture, the partial airfoil array having at least one existing airfoil extending radially between an inner and an outer fairing and an open area where at least one existing airfoil has been removed. The method includes mounting a positioning saddle relative to a base of the fixture, the positioning saddle aligned with the open area, holding a replacement airfoil using the positioning saddle, applying a curable material at an interface between the replacement airfoil and the inner and outer fairing, and curing the curable material while maintaining a relative position between the replacement airfoil and the inner and outer fairing.