Composite Booster Spool with Separable Blades
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Solution Overview
Problem
Current gas turbine engine spools, especially in the low-pressure compressor or booster section, are difficult to maintain due to their metallic or composite/metallic construction, requiring replacement of entire assemblies or large sections when a single blade breaks, which increases complexity and weight, hindering weight reduction and performance improvement.
Innovation Solution
A composite booster spool with separable composite blades that are inserted radially through holes in the spool, allowing for individual blade replacement and formed from materials like ceramic matrix, carbon, or polymeric composites, reducing weight and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic or composite/metallic spools with integrally formed blades are used, then structural strength and rigidity are improved, but weight increases and maintenance complexity increases
Solution Approach 1:
The spool assembly is segmented into separable components: the spool body and individual blades. Blades are inserted through holes in the spool and retained by retention features, allowing the blades to be independent replaceable parts rather than being integrally formed with the spool. This segmentation enables weight optimization by using lighter composite materials for blades while maintaining overall structural strength.
2Stability of the object's composition
If metallic or composite/metallic spools with integrally formed blades are used, then structural rigidity is improved, but maintenance complexity and replacement difficulty increase
Solution Approach 1:
The integral connection between spool and blades is segmented into a modular assembly with retention features. Blades can be individually removed and replaced by extracting them from the spool holes, enabling field serviceability without replacing the entire spool assembly. This maintains structural rigidity through proper retention while dramatically improving maintenance ease.
Solution Approach 2:
Blades are extracted from the integral structure and made removable through the retention feature mechanism. The retention features hold blades in position during operation but allow for deliberate extraction when maintenance is needed, separating the operational rigidity requirement from the maintenance accessibility requirement.
3Weight of moving object
If composite materials are used for spool and blades, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The composite structure is segmented into spool and blade components that can be manufactured separately using optimized composite layup techniques. This allows each component to be manufactured with appropriate fiber orientations and material properties for its specific function, then assembled through the retention feature mechanism, reducing overall manufacturing complexity compared to forming a single complex integral composite structure.
Data Source
AI summary
According to present embodiments or aspects thereof, a composite booster spool with separable composite blades is provided. The blades are inserted radially from within the inner circumference of the spool and extend outwardly through the spool. The system provides a reduced weight assembly as compared to prior art metallic or composite/metallic combination systems. Additionally, the blades are separable which results in a more field-serviceable assembly over a fully integral system wherein the blades and spool are integrally formed from composites or combination of metal and composites.