Compressor Rotor Destacking Tool With Bore-Locked Legs
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Solution Overview
Problem
Current tooling used for disassembling gas turbine engine rotor stages can slip or move during operation, potentially damaging costly integral-bladed rotors, necessitating extensive repair or replacement.
Innovation Solution
A disassembly tool with legs and a puck system is installed into the rotor bore, featuring keys that engage a groove to secure the tool, preventing it from slipping and providing a stable reaction surface for applying an axial force to separate rotor stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If current tooling is used for disassembly, then the pulling force can be applied to separate rotor stages, but the tooling may slip or move during operation causing damage to rotor stages
Solution Approach 1:
The disassembly tool is divided into multiple legs (typically three) that are independently positioned around the rotor bore. Each leg can be individually adjusted and secured, allowing the tool to better conform to the rotor geometry and distribute forces evenly, thereby preventing slippage while maintaining the necessary pulling force.
Solution Approach 2:
The legs are pre-positioned and secured to the rotor bore before the actual disassembly operation begins. This preliminary positioning ensures that the tooling is firmly established and cannot slip during force application. The legs are inserted through the rotor bore and secured to provide a stable foundation before the pneumatic ram applies the separating force.
2Force
If higher pulling force is applied to separate rotor stages, then the stages can be separated more effectively, but the risk of damaging the rotor stages increases
Solution Approach 1:
The legs are designed with specific geometric features including angled surfaces and positioning elements that concentrate the applying force at precise locations on the rotor bore. This localized force application ensures that the separating force is transmitted efficiently to the rotor stages without creating stress concentrations that could damage the rotor blades or structure. The force is distributed across multiple contact points rather than concentrated at a single point.
Solution Approach 2:
The tooling design incorporates features that prevent excessive or uncontrolled force application. The legs are secured in a manner that allows for controlled force transmission, and the overall tool structure is designed to prevent sudden movements or slippage that could cause impact damage. The gradual engagement of the legs provides a cushioning effect that protects the rotor stages from shock loads during the disassembly process.
3Productivity
If traditional tooling is used, then the disassembly process can proceed, but extensive repair or replacement may be needed due to potential damage
Solution Approach 1:
The disassembly tool is designed to be self-securing through the leg positioning and locking mechanism. Once the legs are inserted into the rotor bore, they automatically position themselves and secure without requiring additional tooling or complex installation procedures. This self-service feature maintains high productivity while ensuring the tool remains stable throughout the operation, eliminating the need for repairs due to tooling-induced damage.
Data Source
AI summary
A disassembly tool for a rotor assembly of a gas turbine engine includes a plurality of legs configured for installation into a rotor bore of a rotor of the rotor assembly. Each leg includes one or more keys extending radially inwardly toward a center of the rotor bore. A puck is configured for installation into the rotor bore radially inboard of the plurality of legs. The puck includes a groove receptive of the one or more keys to retain the puck to the plurality of legs.