Compressor Vane Diaphragm Segmentation and Elastomeric Sealing
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Solution Overview
Problem
Prior gas turbine engine compressor diaphragm designs face manufacturing issues, airfoil cracking, and durability problems due to full-circle ring assemblies, which lead to operating stresses and wear at mating surfaces.
Innovation Solution
A novel configuration featuring a vane pack assembly with elastomeric seals and a clamshell-type seal box, where vane segments are fastened together with fasteners and elastomeric seals providing sealing and vibration damping, and a seal box design that enhances durability and assembly techniques without modifying the existing compressor case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If full-circle rings with slots are used for airfoils to slide through and weld, then the compressor diaphragm can be assembled, but airfoil cracking occurs at weld joints during operation and durability issues arise
Solution Approach 1:
The compressor diaphragm is divided into multiple vane segments (typically 3-5 segments) instead of using a full-circle ring. Each segment contains airfoils that are integrally formed with the segment structure, eliminating the need for welding airfoils to continuous rings. The segments are then assembled together using elastomeric seals and fasteners, which resolves the cracking issue while maintaining assembly feasibility.
Solution Approach 2:
Elastomeric seals are introduced as intermediary elements between the vane segments to provide sealing and damping functions. These seals replace the welded joints and provide a flexible, non-rigid connection that accommodates thermal expansion and vibration without causing cracks, while still maintaining the structural integrity of the diaphragm assembly.
2Ease of manufacture
If vane segments are fastened together, then assembly is simplified, but manufacturing precision and sealing at interfaces become critical challenges
Solution Approach 1:
The elastomeric seals change their physical parameters (compression, deformation) under operational conditions to maintain sealing effectiveness. The seals are designed to be compressed between the vane segments during assembly, creating a interference fit that ensures sealing while accommodating manufacturing tolerances. This parameter change allows the system to function effectively even with moderate manufacturing precision.
Solution Approach 2:
The vane segment assembly uses composite construction combining rigid vane segment structures with flexible elastomeric seal materials. This composite approach allows the rigid segments to maintain structural integrity while the elastomeric seals provide the necessary sealing and damping functions, bridging the gap between assembly simplicity and sealing precision requirements.
3Device complexity
If traditional seal designs are used, then the compressor case structure is simple, but sealing durability and vibration damping are insufficient
Solution Approach 1:
The elastomeric seals provide dynamic sealing capabilities, allowing the seal interface to adapt to vibrations and thermal expansions during compressor operation. Unlike rigid seals, the elastomeric material can deform and recover, maintaining sealing contact under varying operational conditions, which significantly improves sealing durability and vibration damping without complicating the overall case structure.
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 solution reduces operating stresses and wear, improves manufacturing tolerances, and enhances durability by using elastomeric seals and a seal box design that provides better sealing and damping, resulting in a more reliable and durable compressor diaphragm assembly.
Implementation Method 1
an elastomeric seal that is located in the recessed portion to provide both sealing and vibration dampening capabilities
Implementation Method 2
an elastomeric seal that is located in the recessed portion to provide both sealing and vibration dampening capabilities
Data Source
AI summary
A compressor diaphragm for a gas turbine engine having improved wear capability, manufacturability, and assembly techniques is disclosed. The diaphragm includes a shiplap-type joint at an outer vane platform for connecting to adjacent vane assemblies and a clamshell-like assembly of a seal box secures and seals regions around the inner vane platform of the compressor diaphragm so as to reduce wear between the seal box and the vane assemblies. The inner platform of the diaphragm segments are fastened to each other through circumferentially-oriented fasteners at the inner diameter platform.