Composite Airfoil Trunnion Assembly With Braided Spar Integration
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Solution Overview
Problem
Existing airfoil assemblies in turbine engines face challenges in efficiently coupling the airfoil to the trunnion, leading to complex assembly processes and maintenance difficulties due to the use of laminated spars within flared sockets, which are time-consuming and labor-intensive.
Innovation Solution
The airfoil assembly incorporates a composite fiber braided over an insert and a portion of the spar, with a skin overlaying both, forming a unitary body through curing, simplifying the assembly process and reducing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laminated spars are used within flared sockets to couple the airfoil to the trunnion, then structural strength is achieved, but assembly complexity and manufacturing burden increase significantly
Solution Approach 1:
The patent merges the spar and airfoil into a single integrated composite structure. The spar is formed as an integral part of the airfoil using composite materials, eliminating the need for separate laminated spars to be installed within flared sockets. This integration reduces assembly complexity while maintaining structural strength through the continuous composite construction.
Solution Approach 2:
The patent employs composite materials to create a unified spar-airfoil structure. The composite construction allows the spar and airfoil to be manufactured as one piece, reducing the number of assembly steps and eliminating complex fitting procedures while achieving the required structural strength through the properties of the composite material.
2Strength
If laminated spars within flared sockets are used to couple the airfoil to the trunnion, then structural integrity is maintained, but manufacturing time and labor requirements increase
Solution Approach 1:
By merging the spar and airfoil into a single composite structure, the patent eliminates multiple manufacturing steps including the installation of separate spars within flared sockets. The integrated construction can be manufactured in a single continuous process, significantly reducing manufacturing time and labor requirements while preserving structural integrity.
Solution Approach 2:
The spar is pre-formed as an integral part of the airfoil during the composite manufacturing process, eliminating the need for subsequent assembly operations. This preliminary integration of the spar structure into the airfoil during manufacturing reduces post-manufacturing time and labor for assembly operations.
3Ease of repair
If separate components are used for the spar and airfoil coupling, then ease of repair is maintained, but assembly and disassembly become time-consuming
Solution Approach 1:
The patent segments the composite structure into distinct functional regions while maintaining overall integration. The spar and airfoil are formed as one piece but with clearly defined structural zones that can be independently accessed and repaired. This segmentation within integration allows for easy repair while reducing assembly time compared to separate components.
Solution Approach 2:
The composite construction provides a unified structure that can be repaired by targeting specific composite layers or regions. The integrated nature of the composite material allows for efficient repair processes while the material properties enable maintenance operations to be performed without requiring complete disassembly, thus reducing assembly time while maintaining ease of repair.
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
This configuration reduces manufacturing burdens and simplifies assembly and disassembly, enhancing the efficiency and ease of maintenance of the airfoil assembly.
Implementation Method 1
A composite fiber is braided over the insert and at least a portion of the spar
Implementation Method 2
forming a unitary body through curing
Data Source
Figure 1
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Figure 3
AI summary
An airfoil assembly (130) and a method of forming the airfoil assembly (130), the airfoil assembly (130) having a trunnion (134), a spar (136), a skin (180), and an insert (172). The trunnion (134) having a flared socket (164) with an open top (170). The spar (136) extending from the flared socket (164) and through the open top (170). The spar (136) having a first end (160) located within the flared socket (164). The skin (180) having a braided or woven fiber.