Ceramic Turbine Vane Assembly for Throat Area Tolerance
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Solution Overview
Problem
The integration of ceramic matrix composite materials into gas turbine engine vanes poses challenges due to variations in size and shape during the fabrication process, making it difficult to achieve acceptable tolerances for optimal performance.
Innovation Solution
A method involving the fabrication, inspection, and selective arrangement of turbine vanes to achieve a throat area within a predetermined tolerance, using adaptive machining and individualized coating techniques to ensure precise sizing and shaping, and employing multiple tools to form vanes with varying sizes and shapes to optimize gas flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ceramic matrix composite materials are used to fabricate turbine vanes, then high-temperature capability is improved, but manufacturing precision deteriorates due to numerous opportunities to introduce variation in size and shape
Solution Approach 1:
The patent applies preliminary action by measuring the actual dimensions of each vane segment before assembly and using these measurements to calculate the specific arrangement configuration that will achieve the target throat area. This pre-planning of the arrangement based on actual measured dimensions allows the system to compensate for manufacturing variations and achieve precise throat area control despite the inherent imprecision in CMC fabrication
Solution Approach 2:
The patent employs parameter changes by adjusting the arrangement configuration of vane segments based on their measured dimensions. The system calculates optimal angular positions and adjacencies to achieve the desired throat area, transforming the problem from one of manufacturing precision to one of configurable arrangement. This allows the throat area parameter to be controlled within tight tolerances despite variations in individual segment dimensions
2Manufacturing precision
If individualized coating techniques and adaptive machining are used to ensure precise sizing, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by allowing each vane segment to have slightly different dimensions and properties based on its actual measured characteristics. Rather than requiring all segments to meet strict dimensional tolerances, the system accepts local variations and compensates through the arrangement calculation, which optimizes the overall throat area based on the specific properties of each segment
Solution Approach 2:
The patent uses copying by creating a digital model or representation of the actual measured dimensions of each vane segment. This digital copy is then used in the arrangement calculation to determine the optimal configuration, eliminating the need for physical trial-and-error assembly and reducing the complexity of the fabrication process
3Adaptability or versatility
If multiple tools are used to form vanes with varying sizes and shapes, then adaptability is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent applies dynamics by making the vane assembly configuration adaptable and reconfigurable. The system calculates the optimal arrangement based on the actual dimensions of available segments, allowing the throat area to be dynamically optimized for different operating conditions. This dynamic arrangement approach allows the use of segments with varying dimensions while maintaining precise throat area control
Solution Approach 2:
The patent employs segmentation by dividing the turbine vane assembly into multiple independent vane segments that can be individually measured, evaluated, and arranged. This segmentation allows the system to accommodate variations in individual segment dimensions produced by multiple tools while achieving the desired overall throat area through optimized arrangement of the segmented components
Data Source
AI summary
A gas turbine engine includes a compressor, a combustor, and a turbine arranged around an axis. The turbine includes a turbine vane assembly. A method for creating the turbine vane assembly includes fabricating a plurality of turbine vanes comprising ceramic matrix composite material and selecting and arranging the turbine vanes to form a turbine vane assembly.