Compressor Variable Vane Stagger Angle Measurement Using Inertial Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current compressor variable angle measurement systems for gas turbine engines are prone to operator errors and lack the accuracy needed to optimize compressor performance, leading to inefficiencies in fuel consumption and aerodynamic stability due to mechanical tolerance stack-ups and inadequate data fidelity.
Innovation Solution
A compressor variable angle measurement system comprising a gauge assembly with an inertial measurement unit, vane contact cushions, and a radial setting pin, connected to a computing device, which allows for precise determination and adjustment of variable vane stagger angles, reducing operator sensitivity and improving data fidelity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional inclinometers with mechanical contact points are used to measure vane angles, then the measurement process is simple and robust, but operator sensitivity and measurement precision deteriorate due to manual operation and mechanical tolerance stack-ups
Solution Approach 1:
The patent replaces traditional mechanical inclinometers with electrical contactors and mechanical contact points with an optical sensor system. The optical sensor non-contactly measures the vane angle by detecting the position of the vane relative to the datum plane, eliminating mechanical tolerance stack-ups and operator sensitivity issues while achieving higher measurement precision.
Solution Approach 2:
The patent introduces a reflective surface attached to the vane as an intermediary element. The optical sensor measures the angle by detecting the position of this reflective surface rather than directly contacting the vane, enabling non-contact measurement while maintaining accuracy and eliminating the need for direct mechanical contact.
2Reliability
If margins are introduced in the design to cover worst case scenarios of noncompliance, then reliability is improved, but compressor efficiency and acceleration performance deteriorate due to compromised aerodynamics
Solution Approach 1:
The patent performs preliminary measurement and adjustment of vane angles during the assembly process using the high-precision optical measurement system. By accurately setting the stagger angles before operation, the system eliminates the need for design margins that would otherwise be required to cover measurement uncertainties and tolerance stack-ups, thereby maintaining both reliability and compressor efficiency.
3Ease of manufacture
If multiple sources of mechanical tolerance are present in variable vane setting, then ease of manufacture is improved, but manufacturing precision deteriorates due to tolerance stack-ups affecting stagger angle accuracy
Solution Approach 1:
The patent replaces mechanical measurement and setting methods with an optical measurement system that is not affected by mechanical tolerances. The optical sensor measures the actual vane angle during assembly, allowing for real-time verification and adjustment, thereby achieving high stagger angle precision without compromising ease of manufacture.
Solution Approach 2:
The patent implements a feedback mechanism where the optical sensor continuously monitors the vane angle during the assembly process. The measurement data is used to verify and adjust the stagger angle setting, ensuring that the final position meets the required precision specifications regardless of accumulated mechanical tolerances during assembly.
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 achieves accurate measurement of +/-0.2-degree aerodynamic stagger angles, enhancing compressor efficiency and fuel burn performance by minimizing malschedule uncertainty and allowing for informed engine design modifications.
Implementation Method 1
An inclinometer or clinometer is an instrument used for measuring angles of slope (or tilt), elevation, or depression of an object with respect to gravity's direction.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A compressor variable angle measurement system for guiding the positioning variable vanes supported on a penny of a compressor of a gas turbine engine. The system comprising a gauge assembly that is connectable to a computing device the gauge assembly comprises a base plate and a clamp arm. The baseplate has a first section and a second section, the first section having a first trailing edge vane engaging portion, a second trailing edge vane engaging portion, at least three vane contact portions, and a radial setting pin, the second section having an inertial measurement unit, the radial setting pin being configured to contact the penny that supports the vane. The clamp arm is pivotally attached to the baseplate and has a first section that has at least one vane contact portion, the first section of the clamp arm being spring urged towards the first section of the baseplate. The gauge assembly is configured to removably grip a variable vane between the vane contact portions of the baseplate and the at least one vane contact portion of the clamp arm and on the leading edge vane engaging portion and the trailing edge vane engaging portion of the base plate, the stagger angle of the variable vane with respect to the radial setting pin being determined by the computing device from measurements made by the inertial measurement unit.