Compressor Diffuser Shroud Alignment via Extraction
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Solution Overview
Problem
The assembly of motor driven compressors for aircraft inert gas generation systems is time and labor intensive due to the need for precise alignment and clearance of rotating parts, which increases manufacturing burden and requires precise tolerances, impacting system weight.
Innovation Solution
A compressor diffuser and shroud design with a specific sealing lip ratio and a cylindrical alignment tool for precise alignment and sealing, reducing the complexity of assembly by using a diffuser portion, compressor inlet portion, and shroud portion with a curvature to align with the compressor rotor, and coupling with a bearing support plate using fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precision-machined alignment pins are used to ensure proper alignment and clearance of rotating parts, then manufacturing precision is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent removes the alignment pins from the final assembly by using a temporary alignment tool during manufacturing only. The alignment features are extracted as a temporary aid rather than a permanent component, eliminating the need for precision-machined pins in the final product while maintaining alignment precision during assembly.
Solution Approach 2:
A temporary cylindrical alignment tool is introduced as an intermediary device during the assembly process. This tool provides the necessary alignment precision between the compressor housing and diffuser/shroud assembly, but is removed after assembly, avoiding the need for permanent alignment pins in the final product.
2Manufacturing precision
If alignment pins are incorporated into the static parts, then manufacturing precision is improved, but system weight increases
Solution Approach 1:
The alignment function is extracted from permanent structural components and performed by a temporary tool during assembly only. This eliminates the need to incorporate weight-bearing alignment pins into the static parts of the compressor, reducing overall system weight while maintaining alignment precision during the assembly process.
3Manufacturing precision
If precise tolerances are specified for static parts to receive alignment pins, then manufacturing precision is improved, but manufacturing time and cost increase
Solution Approach 1:
The temporary cylindrical alignment tool serves as an intermediary that provides precise alignment during assembly without requiring the static parts to be precision-machined to tight tolerances. The alignment tool itself is machined to precision, but this is a one-time manufacturing cost for a temporary tool rather than permanent precision requirements for all static components, reducing overall manufacturing time and cost.
Data Source
AI summary
An aspect includes a compressor diffuser and shroud for a motor driven compressor assembly. The motor driven compressor assembly includes a first stage compressor and a second stage compressor. The compressor diffuser and shroud of the first stage compressor includes a diffuser portion, a compressor inlet portion, and a shroud portion. The diffuser portion includes a diffuser portion outer lip having a first sealing lip outer diameter to provide a first sealing interface to a first stage compressor housing. The compressor inlet portion includes an inlet portion outer lip having a second sealing lip outer diameter to provide a second sealing interface. The shroud portion includes a curvature between the diffuser portion outer lip and the inlet portion outer lip to align with a first stage compressor rotor, where a ratio of the first sealing lip outer diameter to the second sealing lip outer diameter is between 1.622 and 1.628.