Turbine Compressor Rotor Assembly Thermal Expansion
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Solution Overview
Problem
The assembly of compressor rotors for aircraft gas turbines is hindered by issues such as out-of-tolerance installation, misalignment, and deformation, leading to frequent disassembly and reassembly, especially in high-pressure compressors with large diameter disks, which results in significant time losses and potential shaft line failures.
Innovation Solution
The method involves axial packing with specific pressure ranges and controlled temperature adjustments for each disk assembly, including heating and cooling steps to minimize misalignment and deformation risks, and precise measurement and alignment procedures using the GENSPECT system to ensure concentricity and flatness within tolerances, along with predictive calculations for optimal installation angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional assembly methods are used without temperature control, then the assembly process is simpler and faster, but misalignment and deformation occur leading to out-of-tolerance installation
Solution Approach 1:
The patent applies temperature parameter changes to the disks during assembly. Disks are heated to expand them for easier installation, then cooled to contract and secure them tightly, achieving precise concentricity and flatness without complex mechanical alignment devices
Solution Approach 2:
The patent performs preliminary temperature control actions on the disks before assembly. By pre-heating or pre-cooling disks to specific temperatures, the assembly is prepared in advance to achieve proper fit and alignment, preventing misalignment issues during the actual assembly operation
2Manufacturing precision
If repeated disassembly and reassembly is performed to correct installation errors, then installation accuracy may be improved, but time loss increases significantly
Solution Approach 1:
The patent replaces mechanical trial-and-error alignment methods with thermally-controlled dimensional adjustment. By using temperature to control disk dimensions, the system achieves precise installation on the first attempt without requiring repeated mechanical disassembly and reassembly operations
3Ease of manufacture
If original dimensional data is unavailable for maintenance, then part replacement becomes necessary, but cost and time increase
Solution Approach 1:
The patent creates dimensional copies or records of disk specifications during manufacturing. These dimensional data copies are stored and used during maintenance to guide the assembly process, eliminating the need to physically reference original parts and enabling accurate reassembly without retrieving original dimensional data
4Reliability
If axial packing pressure is increased to improve assembly stability, then part detachment risk decreases, but deformation risk increases
Solution Approach 1:
The patent changes the temperature parameter of the disks to control their dimensional state during assembly. By heating disks to expand them or cooling to contract them, the system achieves proper fit and stability without requiring excessive axial packing pressure that would cause deformation
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
This approach reduces the frequency of disassembly and reassembly, minimizes shaft line failures, and ensures accurate assembly within tolerances, thereby enhancing the reliability and efficiency of the compressor rotor installation process.
Implementation Method 1
prior to assembling the sealing disk with said at least one first rotor disk, the sealing disk is heated to a temperature ranging from 80° C. to 140° C., prior to assembling the intermediate disk with said at least one first rotor disk, the intermediate disk is heated to a temperature ranging from 120° C. to 160° C.
Implementation Method 2
said at least one second rotor disk is cooled down: b1) to a temperature ranging from −70° C. to −110° C.
Implementation Method 3
axial packing (X1) is applied with a pressure ranging from 40×105 to 60×105 Pa
Data Source
AI summary
The invention relates to the manufacturing of a rotor (23) of a high-pressure compressor. Various installation constraints are proposed in terms of temperature, angle and unevenness and/or runout defects to be considered. For example, when installing the sealing disk (25) on the first drum (27) of the rotor and/or the intermediate disk (29) on the first drum assembled with the sealing disk, axial packing (X1) is applied with a pressure ranging from 40 to 60×105 Pa.