Axial Flow Compressor Assembly Segmentation
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Solution Overview
Problem
Current axial flow 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 method involves assembling an axial flow compressor with a tubular casing encasing a rotatable shaft, paired rotor segments with bladed discs, and a banded stator segment comprising outer and inner flowpath rings with vanes, along with a sealing mechanism to reduce complexity and material costs, using a sequential installation process for rotor and vane segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional axial flow compressor designs are used, then reliable fluid compression is achieved, but manufacturing cost and operational cost are high
Solution Approach 1:
The compressor is divided into modular segments including a tubular casing segment, rotor segment, and stator segment that can be manufactured separately and assembled together. This segmentation enables simplified manufacturing processes for each component while maintaining overall system reliability for fluid compression.
2Ease of manufacture
If material substitution with composite materials is implemented, then procurement and machining costs are reduced, but overall cost savings are insufficient for expendable applications
Solution Approach 1:
The design accepts that the compressor is expendable and optimizes for single-use cost-effectiveness. The segmented architecture allows for economical manufacturing of disposable units without requiring expensive durable materials or complex assembly, achieving cost savings suitable for expendable applications.
3Reliability
If complex sealing mechanisms and multiple fasteners are used, then assembly reliability is improved, but device complexity and material costs increase
Solution Approach 1:
The casing segment integrates sealing surfaces and positioning features directly into the tubular structure, eliminating the need for separate sealing mechanisms and multiple fasteners. The rotor and stator segments are retained within the casing through simplified retention methods, reducing overall device complexity while maintaining assembly reliability.
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 design achieves cost savings through simplified assembly and reduced material costs, with fewer fasteners and seals, while maintaining effective fluid compression capabilities for various applications.
Implementation Method 1
said stator segment further comprising an abradable ring extending axially from said outer flowpath ring and radially between the blade tips of one of said rotor segments and said casing
Data Source
AI summary
An axial flow compressor comprises a tubular casing which encases a rotatable shaft, a pair of rotor segments coupled to the rotatable shaft and each comprising a bladed disc, and a banded stator segment disposed between the pair of rotor segments and comprising a plurality of stator vanes extending between an outer flowpath ring and an inner flowpath ring. A method of assembling an axial flow compressor comprises installing a rotor segment inside a tubular compressor casing, installing a vane segment adjacent the installed rotor segment, and repeating the steps of installing a rotor segment and vane segment until a desired number of rotor segment and vane segment pairs are installed.