Gas Turbine Combustor Assembly Using Integral Flange Joint
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Solution Overview
Problem
Gas turbine engine combustor assembly techniques face challenges in maintaining alignment without fasteners until assembly is complete, and there is a need for improved efficiency and reduced fastener usage to simplify maintenance and enhance thermal, transfer, and propulsive efficiencies.
Innovation Solution
A combustor assembly for a gas turbine engine that includes a combustor shell, a turbine rotor, a vane pack, a tangential on-board injector (TOBI), and a case, secured by a joint with integral flanges and fasteners, where the combustor flange, TOBI flange, and case flange are secured using different fasteners, including nuts and bolts, and an interference fit relationship between the combustor and TOBI flanges, and the case flange, allowing for alignment and secure assembly without temporary fasteners during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple fasteners are used to secure combustor components, then the alignment and security of components is improved, but the complexity of assembly and maintenance increases
Solution Approach 1:
The combustor assembly is divided into modular components (combustor shell, TOBI, case, vane pack) that can be assembled independently and then connected through the joint assembly. This segmentation allows each component to be manufactured and tested separately, reducing overall assembly complexity while maintaining reliable connections through standardized flange interfaces
Solution Approach 2:
The joint assembly serves multiple functions simultaneously: it secures the combustor shell, TOBI, and case together; provides alignment features through integral flanges; and creates sealed combustion chambers. This multi-functionality reduces the need for separate alignment fixtures and temporary fasteners, simplifying the overall assembly process
2Manufacturing precision
If temporary fasteners are used during assembly, then alignment is maintained, but the number of fasteners and assembly steps increases
Solution Approach 1:
Alignment features (such as precision-machined flange surfaces and locating pins) are built into the components during manufacturing. This preliminary action ensures that when components are brought together, they self-align without requiring temporary fasteners or external alignment tools, thereby maintaining precision while improving assembly efficiency
Solution Approach 2:
The joint assembly acts as an intermediary structure that facilitates the connection between combustor components. It provides a standardized interface with integral flanges that simplify the connection process, eliminating the need for temporary fasteners by incorporating permanent fastening mechanisms directly into the joint design
3Ease of repair
If the number of fasteners is reduced, then maintenance is simplified, but the security of component connection may be compromised
Solution Approach 1:
Multiple fastening functions are merged into a single integrated joint assembly. The joint incorporates flanges, fasteners, and sealing surfaces all in one component, which simplifies maintenance (the entire joint can be replaced as one unit) while maintaining strong connections through the combined structural integrity of all its elements
Solution Approach 2:
The fastener configuration is optimized by changing parameters such as fastener size, material properties, and distribution patterns. This allows fewer fasteners to achieve the same or greater connection strength, thereby simplifying maintenance while maintaining security
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 enables efficient assembly and secure alignment of combustor components with reduced fastener usage, enhancing assembly efficiency and maintaining the desired fit without temporary fasteners, thus improving thermal and propulsive efficiencies in gas turbine engines.
Implementation Method 1
a joint for securing the combustor shell, tangential on board injector and case together. The joint has a combustor flange integral to the combustor shell, a tangential on board injector flange integral to the tangential on board injector and a case flange integral to the case, wherein the combustor flange, the tangential on board injector flange and the case flange are secured together
Implementation Method 2
the combustor flange and axially extending portion are provided in an interference fit relationship with one another. The case flange and axially extending portion are provided in an interference fit relationship with one another
Data Source
Figure 1
Figure 2~4
Figure 3A~3B
AI summary
A combustor assembly for a gas turbine engine includes a combustor shell, a TOBI, a case, and a joint for securing the combustor shell, TOBI and case together. The joint has a combustor flange integral to the combustor shell. A TOBI flange is integral to the TOBI and a case flange is integral to the case. The combustor flange, the TOBI flange and the case flange are secured together.