Airfoil Assembly with 3D Leading Edge Element

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Solution Overview

Problem

Turbine engine components, such as stator vanes and rotating blades, face extreme mechanical and thermal stresses due to high temperatures and unsteady airflow, requiring advanced materials and designs to manage these stresses effectively while reducing weight for increased efficiency.

Innovation Solution

The airfoil assembly features a leading edge element with a 3-D geometry that includes variations in both chord and camber, secured to a trailing edge element, allowing for improved load management and noise reduction, and enabling the use of different materials for each edge to optimize performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If composite airfoils are used to reduce weight, then weight is reduced and efficiency is increased, but the ability to withstand impact from foreign objects and unsteady pressure is compromised

Engineering Contradiction:

Improveairfoil weightVSAvoidimpact resistance

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The airfoil assembly combines composite airfoil material with a metal leading edge element, creating a hybrid structure that leverages the weight advantages of composites while incorporating the impact resistance of metal at the critical leading edge position

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The leading edge element is specifically positioned at the leading edge of the airfoil where impact from foreign objects and exposure to unsteady pressure occur most frequently, providing localized reinforcement exactly where needed rather than throughout the entire airfoil structure

Inventive Principle:

Principle #3Local quality

2Strength

If a metal leading edge element is added to protect against impact, then impact resistance is improved, but the complexity of the airfoil structure increases

Engineering Contradiction:

Improveimpact resistanceVSAvoidairfoil structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The airfoil is divided into distinct segments: the composite airfoil body and the separate metal leading edge element, allowing each component to be optimized independently and simplifying manufacturing and maintenance processes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The leading edge element serves as an intermediary component that interfaces between the composite airfoil structure and the external environment (foreign objects, unsteady pressure), protecting the main airfoil body from direct exposure to harsh conditions

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If the leading edge element has 3-D geometry with chord and camber variation, then aerodynamic performance is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveaerodynamic performanceVSAvoidgeometry precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The leading edge element incorporates variable geometric parameters including chord length variation and camber variation along its span, optimizing aerodynamic performance by matching the local flow conditions at different positions on the airfoil

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10539025B2Airfoil assembly with leading edge element

Publication Date: 2020.01.21 GENERAL ELECTRIC CO

AI summary

An airfoil assembly including a composite body having a mounting edge and a trailing edge which is secured to a leading edge element defining a 3-D leading edge geometry with both chord and camber variation.