Blade Plug Fluid Communicator for Cavity Pressure Equalization

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Solution Overview

Problem

Aircraft blades experience increased stresses due to differential pressure between trapped ambient air in their cavities and altitude air, which is not addressed by existing technologies.

Innovation Solution

A method and device for communicating fluid into or out of a blade cavity using a blade plug with a movable plug cap that allows for fluid passage, enabling the evacuation or pressurization of the cavity during manufacturing, thereby minimizing or eliminating differential pressure stresses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the blade cavity is sealed with a plug during manufacture, then the blade structure is simplified and manufacturing is easier, but differential pressure stresses are imposed on the blade during operation at altitude

Engineering Contradiction:

Improveblade manufacturing simplicityVSAvoiddifferential pressure stress on blade

Core Design Contradiction:

Ease of manufactureVSStress or pressure

Solution Approach 1:

The patent applies preliminary action by evacuating air from the blade cavity during the manufacturing process before the plug is permanently installed. This creates a vacuum or reduced pressure environment inside the cavity, so that when the blade operates at altitude, the pressure differential between the trapped air and external ambient pressure is minimized or eliminated, thereby preventing the harmful stress that would otherwise develop during flight

Inventive Principle:

Principle #10Preliminary action

2Productivity

If ambient air is trapped within the blade cavity during manufacture, then the manufacturing process is simpler and faster, but additional stresses are imposed on the blade during flight operation

Engineering Contradiction:

Improvemanufacturing speedVSAvoidblade structural integrity under stress

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent performs air evacuation from the blade cavity as a preliminary action during manufacturing, before the blade enters service. This is accomplished by installing a temporary plug with a passage during assembly, evacuating the air through this passage, and then sealing the passage. This preliminary evacuation prevents the strength issue during operation while maintaining manufacturing efficiency

Inventive Principle:

Principle #10Preliminary action

3Reliability

If a permanent seal is installed in the blade cavity during manufacture, then the blade is ready for immediate operation, but the cavity cannot be pressurized or evacuated to reduce operational stresses

Engineering Contradiction:

Improveblade readiness for operationVSAvoidability to adjust cavity pressure

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent resolves this contradiction by performing the pressure adjustment action preliminarily - evacuating the cavity air during manufacturing before the blade is delivered for operation. The plug design includes a passage that allows this evacuation to occur, and then the passage is sealed to maintain the pressure-reduced state. This provides the adaptability to adjust pressure while ensuring reliability for immediate operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies parameter changes by altering the pressure parameter inside the blade cavity from ambient pressure to a reduced pressure (vacuum) state during manufacturing. This parameter change is achieved by evacuating air through the passage in the plug, and then sealing the passage to maintain the new pressure parameter, thereby reducing the stress parameter during operation

Inventive Principle:

Principle #35Parameter changes

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

The solution effectively reduces or eliminates the stresses on aircraft blades by allowing for the equalization of air pressure within the blade cavity, reducing operational stress and maintaining structural integrity at altitude.

Implementation Method 1

evacuating air from the plug tool prior to operating the fluid communicator as a vacuum to evacuate air from within a blade

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

communicator fluid to or from a blade cavity through the passage using the fluid communicator... allowing for the equalization of air pressure within the blade cavity

Methodology Applied

Scientific EffectPressure equalization: Pressure Gradient

Data Source

PatentUS10464660B2Blade plug for communicating fluid therethrough

Publication Date: 2019.11.05 HAMILTON SUNDSTRAND CORP

AI summary

A method of manufacturing an aircraft blade is provided. The method includes attaching a fluid communicator to a plug tool connected to a blade plug, opening a passage in the blade plug using the plug tool, communicating fluid to or from a blade cavity through the passage using the fluid communicator, and sealing the passage in the blade plug using the plug tool.