Castellated Turbomachine Flanges for Fast Assembly and Flexible Clocking
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Solution Overview
Problem
Current turbomachine component coupling methods are time-consuming due to the large number of fasteners required and limit thrust reverser clocking flexibility, particularly with 36 interface flanges restricting clocking to 10-degree increments.
Innovation Solution
The design features internal and external attachment flanges with radially extending sections and receptacle sections that form mating pairs, including anti-rotation features, allowing for efficient coupling without extensive fastener installation and enabling flexible clocking by positioning anti-rotation flange pairs asymmetrically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bolts and nuts are used to couple turbomachine components at each interface flange, then reliable mechanical connection is achieved, but assembly time increases significantly due to the large number of fasteners required
Solution Approach 1:
The patent combines multiple fastening functions into a single integrated castellated flange structure. The interlocking teeth and receptacles replace numerous individual bolts and nuts, achieving the same mechanical connection reliability with far fewer fasteners. The castellated design allows multiple engagement points to be integrated into one unified coupling mechanism.
Solution Approach 2:
The flange is segmented into multiple castellated teeth that can independently engage with corresponding receptacles. This segmentation allows the connection to be achieved through multiple distributed contact points rather than requiring a single complex fastening system, reducing overall assembly time while maintaining reliability.
2Reliability
If 36 interface flanges are used to provide sufficient coupling points, then mechanical retention is achieved, but thrust reverser clocking flexibility is limited to 10-degree increments
Solution Approach 1:
The castellated flange design incorporates asymmetric tooth profiles and varying receptacle configurations that allow for continuous angular adjustment rather than discrete 10-degree increments. The asymmetric geometry enables smooth rotation and positioning at any angle within the operational range, providing superior clocking flexibility while maintaining secure mechanical retention.
Solution Approach 2:
The coupling system transitions from a static, fixed-position flange arrangement to a dynamic system where the castellated teeth can engage at varying angles. The design allows the thrust reverser to be clocked to different positions continuously, enabling adaptive positioning rather than being constrained to predetermined angular increments.
3Reliability
If multiple fasteners are installed at each of 30-36 interface flanges, then secure component coupling is achieved, but the process becomes excessively time-consuming
Solution Approach 1:
The patent merges the function of multiple individual fasteners into a single castellated flange assembly. Instead of installing numerous separate bolts and nuts at each interface, the interlocking teeth and receptacles provide integrated fastening, dramatically improving assembly efficiency while maintaining coupling security.
Solution Approach 2:
The castellated flange structure is pre-configured with interlocking teeth and receptacles that automatically engage when components are brought together. This preliminary configuration eliminates the need for time-consuming fastener installation procedures, as the coupling mechanism is already prepared to secure the components upon engagement.
Data Source
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AI summary
Turbomachines and methods for coupling first and second turbomachine components are provided. The components include castellated flange arrangements that provide an improved retention method for retaining the components that is far superior in than bolts and nuts, especially for massive unbalance loading.