Axial Compressor Banded Stator Segmentation
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Solution Overview
Problem
Current axial compressors are costly to manufacture and operate, particularly for expendable applications, as material substitution alone is insufficient to achieve significant cost savings.
Innovation Solution
The design incorporates a tubular casing with rotor and stator segments, featuring a banded stator segment with outer and inner flowpath rings, tangs that form an annulus with the casing, and pathways for air flow between the annulus and the main flowpath, utilizing metallic foam fillers for enhanced thermal conductivity and actuating vanes to alter vane angles, which reduces manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If material substitution (metal to composite) is implemented, then procurement and machining costs are reduced, but overall cost savings are insufficient for expendable applications
Solution Approach 1:
The compressor is divided into modular segments including a tubular casing, rotor segments, and stator segments that can be independently manufactured and assembled. The stator segment comprises an outer flowpath ring, inner flowpath ring, and vane assemblies that can be separately produced and then integrated, simplifying manufacturing while maintaining structural integrity
Solution Approach 2:
Multiple functional components are merged into integrated assemblies. The stator segment combines the outer flowpath ring, inner flowpath ring, vanes, and support structures into a single modular unit. The tangs are integrated with the outer flowpath ring to form a unified structure that provides both structural support and flowpath definition
2Productivity
If traditional axial compressor design is used, then compression function is achieved, but manufacturing and operational costs remain high
Solution Approach 1:
The compressor incorporates variable geometry capabilities through actuating mechanisms that can adjust vane angles in real-time. The actuating mechanism includes actuators coupled to the vanes, allowing dynamic adjustment of the stator vane geometry to optimize compression efficiency under different operating conditions
Solution Approach 2:
The compressor design incorporates self-regulating features where the fluid dynamics and structural geometry work together to maintain optimal performance. The annulus formed by the outer flowpath ring and casing, along with the pathway provisions, create self-regulating flow patterns that enhance compression efficiency without requiring complex external control systems
3Volume of moving object
If the outer flowpath ring is positioned close to the casing, then structural compactness is achieved, but cooling efficiency is reduced
Solution Approach 1:
The design creates localized cooling zones through the annulus between the outer flowpath ring and casing. Pathway provisions are strategically positioned to channel cooling fluid through specific regions where heat generation is highest, providing targeted cooling without requiring the entire structure to be expanded
Solution Approach 2:
Cooling is achieved by utilizing the radial dimension through the annulus formation. The outer flowpath ring is positioned radially inward from the casing to create an annular space that serves as a cooling pathway, allowing cooling fluid to flow in the radial direction and extract heat from the compressor components
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
This configuration achieves significant cost savings through simplified design, reduced fasteners, and ease of assembly, while improving cooling and intercooling efficiency, thus lowering operational costs and enhancing compressor performance.
Implementation Method 1
air flow through the pathway is induced by a differential pressure between the air pressure proximate the entry pathway and the air pressure proximate the exit pathway
Implementation Method 2
utilizing metallic foam fillers for enhanced thermal conductivity
Data Source
AI summary
An axial compressor comprises a plurality of compressor stages positioned axially adjacent each other within a casing. Each of the plurality of compressor stages includes a rotor segment and a banded stator segment. An annulus is formed between the casing and an outer flowpath ring of the banded stator segment. A pathway may be provided that establishes an air flowpath between the annulus and another annulus formed by an adjacent stage.