Compressor Rotor Inspection System for Tip Clearance Optimization

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Solution Overview

Problem

Existing systems for inspecting and optimizing compressor rotor placement in gas turbine engines face accuracy issues due to off-centre positioning, leading to blade clearance variations and reduced engine efficiency, with current methods compromising accuracy and increasing the risk of tip rub situations.

Innovation Solution

A rotor blade system utilizing a probe holder with a laser or capacitance probe, combined with a rotor positioner and encoder, to accurately determine and align the compressor rotor within its case, minimizing tip clearance through wireless or wired communication, and featuring non-scratchable materials and unique fixtures for secure attachment and measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If off-centre positioning of the compressor rotor is used to increase clearance in one area, then blade clearance is improved in that area, but tip rub risk increases in opposite areas

Engineering Contradiction:

Improveblade clearanceVSAvoidtip rub risk

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The system dynamically adjusts rotor positioning during operation rather than using fixed off-centre positioning. The rotor positioner can move the rotor radially and axially to optimize clearance distribution across all blade paths, preventing tip rub in any single area while maintaining optimal clearance where needed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system uses probes to continuously measure blade tip clearance and provides feedback to the control system. This feedback enables real-time adjustments to rotor positioning, ensuring that clearance is optimized without creating tip rub conditions in opposite areas of the compressor case.

Inventive Principle:

Principle #23Feedback

2Ease of operation

If shim-based methods are used to position the compressor rotor, then rotor placement is adjusted, but measurement accuracy is compromised

Engineering Contradiction:

Improverotor placement adjustmentVSAvoidclearance measurement accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The system replaces mechanical shim-based positioning with an electrically controlled rotor positioner. This allows for more precise and measurable adjustments to rotor placement, eliminating the inaccuracies inherent in manual shim installation while maintaining ease of operation through electrical control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system uses probes to create accurate digital measurements of blade tip clearance, replacing the indirect and less accurate mechanical measurement methods used with shims. This provides precise measurement data for optimizing rotor positioning.

Inventive Principle:

Principle #26Copying

3Measurement precision

If probe systems are used to measure blade clearance, then measurement capability is provided, but system complexity increases

Engineering Contradiction:

Improveclearance measurement capabilityVSAvoidinspection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The probe system is integrated with the rotor positioner and control system to perform multiple functions: measuring blade clearance, providing feedback for positioning adjustments, and monitoring clearance during operation. This multi-functionality reduces overall system complexity compared to separate measurement and control systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Manufacturing precision

If accurate rotor alignment is achieved, then blade tip clearance is minimized, but air-mass flow losses increase due to blow-by

Engineering Contradiction:

Improverotor alignment accuracyVSAvoidair-mass flow loss

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The system dynamically optimizes rotor positioning to achieve the precise alignment needed to minimize blade tip clearance and prevent blow-by losses. The rotor positioner can make fine adjustments to ensure optimal clearance that prevents air-mass flow losses while maintaining accurate rotor alignment.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system ensures accurate alignment of the compressor rotor, reducing blade tip clearances and enhancing engine performance by providing precise operational parameters, thereby improving air-mass flow and reducing 'blow-by' losses.

Implementation Method 1

a laser probe, capacitance probe or both to scan about a compressor rotor blade path

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

a laser probe, capacitance probe or both to scan about a compressor rotor blade path

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentUS7579844B2Rotor blade system for rotor and rotor case inspection

Publication Date: 2009.08.25 STANDARD AERO SAN ANTONIO

AI summary

The present invention relates to a system used for inspecting the position of a compressor rotor within a compressor rotor case. A compressor rotor blade is moved about the rotor blade path of the compressor rotor case, a probe holder attached to the rotor blade has a scanning device as part of the holder used for gathering information relative to the compressor rotor case. A fixture attached to the compressor rotor gathers information about the position of the compressor rotor with respect to the compressor rotor case to determine the relative position of both the compressor rotor in relation to the compressor rotor case.