Axial Compressor Rotor Assembly With Interstage Shaft Load Redirection
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Solution Overview
Problem
Traditional multi-stage axial compressor rotor assemblies with boltless construction require longer designs due to bearing systems, which can be improved for enhanced space efficiency and bearing system integration.
Innovation Solution
A rotor assembly design with an interstage shaft that tapers radially inward and axially along the central axis, redirecting the load path away from the first rotor stage, allowing for improved bearing system integration and increased space for advanced components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional boltless construction with conical shafts and interference fit engagement is used, then the rotor assembly achieves a compact design, but bearing systems require additional space resulting in a longer rotor assembly
Solution Approach 1:
The interstage shaft extends radially inward between rotor stages rather than only axially, creating a three-dimensional load path that redirects forces away from the first rotor stage. This radial extension allows bearing systems to be integrated more efficiently within the existing axial footprint, reducing the need for additional axial length while maintaining proper bearing support.
Solution Approach 2:
The interstage shaft acts as an intermediary structural element between the first and second rotor stages. By providing this intermediate load-bearing component with radial extension, the design mediates the conflict between compact construction and bearing system requirements, allowing bearing integration without proportionally increasing overall rotor assembly length.
2Adaptability or versatility
If the interstage shaft extends radially inward between rotor stages, then space is created for advanced bearing systems, but the structural complexity of the shaft increases
Solution Approach 1:
The interstage shaft serves multiple functions simultaneously: it provides structural support between rotor stages, redirects load paths away from the first rotor stage, creates space for bearing systems, and maintains rotational integrity. By consolidating these multiple functions into a single component rather than requiring separate elements, the design increases adaptability for various bearing configurations without proportionally increasing overall structural complexity.
3Strength
If the load path is redirected away from the first rotor stage through the interstage shaft, then rotor load capacity is enhanced, but the manufacturing complexity of the tapered shaft increases
Solution Approach 1:
The interstage shaft employs a tapered geometry with varying radial and axial dimensions to optimize load distribution and redirect forces away from the first rotor stage. While tapered geometries can increase manufacturing complexity, modern additive manufacturing and precision machining techniques can produce these complex shapes efficiently. The parameter variations in the shaft geometry are optimized to achieve the desired load path redirection and strength enhancement.
Data Source
AI summary
An axial compressor rotor assembly includes a plurality of rotor disks extending axially along and circumferentially about a central axis between an upstream end and a downstream end. The rotor disks extend radially between an inner radial hub and an outer radial rim, and axially between a forward rim end and a rearward rim end. An airfoil extends spanwise from each of the rotor disks. A first rotor disk is disposed forward of a second rotor disk. The second rotor disk includes an interstage shaft. The interstage shaft includes an outer radial end, an inner radial end, and an arm. The arm extending axially from an outer surface of the interstage shaft to a distal end. The rearward rim end of the first rotor disk is fixedly joined to the distal end of the arm, for example, by inertia welding.