Compressor Blade Lock with Removable Key for Onsite Repair
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Solution Overview
Problem
Conventional axial compressor blade replacement requires disassembly and unstacking of wheels, leading to costly and time-consuming repairs, as the rotor must be removed and taken to a specialized facility for replacement of a single damaged blade.
Innovation Solution
A modified blade assembly with a blade root, keys, and spacers that allows for the replacement of compressor blades without unstacking the wheels, enabling onsite replacement with the rotor installed, using machining techniques to create a profile that fits within the existing groove and provides axial clearance for easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If conventional blade replacement method is used (removing rotor and unstacking wheels), then blade replacement can be performed, but repair time and downtime increase significantly
Solution Approach 1:
The blade is divided into separate components: the blade body and the blade root. The blade root includes a keyway that accepts a key, allowing the blade to be segmented for easier installation and removal without unstacking wheels. This segmentation enables the blade to be replaced independently while maintaining the stacked wheel configuration.
Solution Approach 2:
The key is extracted as a separate removable component from the blade root. The key can be removed to allow the blade to slide out of the groove without requiring the wheel to be unstacked. This extraction of the locking mechanism enables quick blade replacement while keeping the wheel stack intact.
2Ease of repair
If conventional blade replacement method is used (removing rotor and unstacking wheels), then blade replacement can be performed, but manufacturing and repair costs increase
Solution Approach 1:
The blade assembly is segmented into replaceable components (blade, blade root, key) that can be serviced independently. This allows damaged blades to be replaced without the need for specialized facility unstacking operations, reducing repair costs while maintaining structural integrity.
Solution Approach 2:
The blade replacement system is designed to be self-servicing at the operating location. The key removal mechanism allows operators to replace blades without requiring external specialized equipment or facilities, thereby reducing manufacturing and repair costs.
3Ease of operation
If modified blade root profile is used, then axial clearance is provided for easy installation, but blade root structure becomes more complex
Solution Approach 1:
The blade root is segmented with a keyway and key mechanism that provides axial clearance when the key is removed. This segmentation allows the blade to be installed and removed axially without complex disassembly, balancing structural complexity with ease of operation.
Solution Approach 2:
The key acts as an intermediary component between the blade root and the groove. When removed, it provides the necessary axial clearance for blade installation. This intermediary mechanism simplifies the installation process while maintaining a relatively simple blade root structure.
Data Source
AI summary
A blade assembly for a groove of a wheel of rotating machinery is described. The blade assembly includes, a blade root having two longitudinal sides, a base, and a roof, wherein the profile of the longitudinal sides includes a rounded surface, a blade connected to the roof of the blade root, and one or more keys juxtaposed along each longitudinal side of the blade root, each key having an inboard side and an outboard side, wherein the profile of the inboard side of each key is configured to mate with the profile of the blade root. The blade assembly allows replacement of a compressor blade without the need for unstacking the rotor to gain access to the damaged blade.