Composite Guide Vane Assembly with Integral Attachment Web
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Solution Overview
Problem
Conventional metallic guide vanes in gas turbine engines are heavy, leading to high fuel consumption and manufacturing challenges when replacing them with composite materials, as existing fixing methods can weaken the composite structure and introduce manufacturing complexities.
Innovation Solution
A guide vane assembly using fibre-reinforced composite materials with integral aerofoil members and a vane assembly attachment web, allowing for secure attachment to engine rings without compromising strength, and featuring attachment flanges that correspond to engine rings for straightforward assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional metallic guide vanes are used, then structural strength is sufficient, but weight is excessive leading to high fuel consumption
Solution Approach 1:
The patent applies composite materials by forming the guide vane assembly from a single piece of composite material (such as carbon fibre reinforced plastic) that incorporates both the aerofoil members and the attachment web. This composite construction achieves the required structural strength while significantly reducing weight compared to conventional metallic guide vanes, directly resolving the contradiction between weight reduction and maintaining structural integrity.
2Weight of moving object
If composite materials are used for guide vanes, then weight is reduced, but conventional fixing methods weaken the composite structure
Solution Approach 1:
The patent merges the guide vane aerofoil members and the attachment web into a single integral composite structure. The attachment web is formed as an inherent part of the composite material piece, eliminating the need for separate fixing operations that would require drilling or fastening. This integration preserves the structural integrity of the composite material while achieving weight reduction, resolving the contradiction between using composite materials and maintaining reliability.
Solution Approach 2:
The patent segments the guide vane assembly into modular units where individual guide vanes can be independently replaced. Each guide vane assembly is formed from a separate piece of composite material with its own attachment web, allowing individual replacement without affecting the entire stator vane stage. This segmentation improves reliability by localizing potential failures and simplifying maintenance.
3Ease of manufacture
If individual composite guide vanes are assembled using conventional methods, then assembly is possible, but manufacturing complexity increases and cost rises
Solution Approach 1:
The patent combines the guide vane and attachment web into a single integral composite component. This merging eliminates the need for separate manufacturing and assembly operations for the attachment web and guide vane, reducing manufacturing complexity. The single-piece construction requires only one forming operation, simplifying the manufacturing process while maintaining the ability to assemble multiple vanes into a complete stator stage.
Solution Approach 2:
The attachment web is pre-formed as an integral part of each guide vane assembly during the composite forming process. This preliminary action prepares the assembly for straightforward installation onto the engine rings without requiring complex field assembly operations. The pre-integrated attachment web eliminates the need for separate fastening operations, reducing both manufacturing and assembly complexity.
4Use of energy by moving object
If composite guide vanes are used, then fuel consumption is reduced, but repair and maintenance become more complex
Solution Approach 1:
The patent segments the stator vane stage into independent guide vane assemblies, each formed from its own piece of composite material. This segmentation allows individual guide vanes to be replaced without affecting adjacent vanes or requiring disassembly of the entire stage. The modular design with integrated attachment webs simplifies maintenance operations, making composite guide vanes easier to repair despite the advanced material used, thereby resolving the contradiction between fuel efficiency and ease of repair.
Data Source
AI summary
A guide vane assembly for a stator vane stage comprises at least two aerofoil members joined together using a vane assembly attachment web. The vane assembly attachment web may be provided at the inner and/or outer radius of the aerofoil members. The vane assembly attachment web allows the guide vane assembly to be attached to an inner and/or outer attachment ring, thereby forming a stator vane stage. Such an arrangement may allow composite fiber reinforced guide vane assemblies to be readily assembled together to form stator vane stages. Stator vane stages that comprise such composite fiber reinforced guide vane assemblies may be lighter than conventional metallic stator vane stages.