Closed-Loop Shaft Pre-Stretching for Turbine Component Joining
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Solution Overview
Problem
Existing manual systems for pre-stretching turbine shafts are not optimal due to the need for manual control of hydraulic pressure, which diverts operator attention from monitoring the overall status of parts and hydraulic loading.
Innovation Solution
A method and system that automatically control hydraulic pressure to pre-stretch a shaft, using a controller to receive commanded pressure inputs, determine a pressurization schedule, and operate a hydraulic pump and valve to achieve the desired stretch, while also monitoring the stretch via sensors and providing feedback on acceptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control is used to operate the hydraulic pressure system for pre-stretching the shaft, then the operator can directly control the stretching process, but the operator's attention is diverted from monitoring the overall status of parts and hydraulic loading
Solution Approach 1:
The system performs self-monitoring and self-control through automated sensors and control circuits that track hydraulic pressure, shaft stretch, and system status without requiring continuous operator intervention, allowing the operator to focus on overall monitoring
Solution Approach 2:
Sensors provide real-time feedback on shaft stretch and hydraulic pressure to the control circuit, which automatically adjusts the hydraulic valve to maintain proper pre-stretch conditions, creating a closed-loop control system that improves both automation and monitoring capability
2Extent of automation
If automated control is implemented to manage hydraulic pressure and monitor shaft stretch, then operator attention can focus on overall status monitoring, but the system complexity increases
Solution Approach 1:
The control circuit performs multiple functions including pressure regulation, stretch measurement, acceptability determination, and valve control within a single integrated system, reducing the need for separate dedicated components for each function
Solution Approach 2:
The control circuit acts as an intermediary between the sensors and the hydraulic valve, processing sensor signals and automatically actuating the valve without requiring direct operator intervention, thereby simplifying the control architecture while maintaining automation
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 system enables efficient and accurate pre-stretching of turbine shafts, allowing operators to focus on other tasks while ensuring that the shafts are properly stretched within acceptable limits, thereby improving the reliability of turbine assembly.
Implementation Method 1
causing hydraulic fluid to be provided to the fixture at a pressure based on the commanded pressure, to initiate the pre-stretch on the shaft
Implementation Method 2
The shaft is coupled to a first component and extending through a second component... A measured stretch of the shaft is received from a sensor. Determining if the measured stretch is within a range of acceptable stretch
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A method of securing two components under this disclosure could be said to include receiving an input including a commanded pressure for achieving a pre-stretch on a shaft (46) housed within a fixture (34). The shaft (46) is coupled to a first component (36) and extending through a second component (38). In response to receiving the input, causing hydraulic fluid to be provided to the fixture (34) at a pressure based on the commanded pressure, to initiate the pre-stretch on the shaft (46). A measured stretch of the shaft (46) is received from a sensor. Determining if the measured stretch is within a range of acceptable stretch; and based on a determination that the measured stretch is within the range of acceptable stretch, causing an indication of acceptability. The indication of acceptability being an instruction to tighten a nut (48) to secure the shaft (46) to the second component (38). A system and a controller are also disclosed.