Coupling Flange Shim Grooves for Wear and Tilt Adjustment
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Solution Overview
Problem
Industrial machine components, such as turbomachine coupling flanges, experience wear and deformation, requiring complex and expensive repairs involving complete removal and machining or the use of radially extending shims, which are also time-consuming and costly.
Innovation Solution
A coupling flange design with radially spaced grooves and shims that allow for independent adjustment and replacement without removing the flange, enabling precise positioning and tilt control, reducing downtime and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shroud coupling flange is completely removed and machined to form a new axially forward surface, then the seal element can seal against the rotating blade, but the repair requires complex and precise machining and complete removal of fasteners, making it very time consuming and expensive
Solution Approach 1:
The coupling flange is divided into the flange body and separate shim components. The shims are inserted into grooves on the flange surface, allowing the sealing function to be separated from the flange structure itself. This segmentation enables the shims to be replaced independently without removing the entire flange or fasteners.
Solution Approach 2:
The sealing function is extracted from the flange body and implemented through separate shim components. These shims can be individually removed and replaced to address wear or deformation, eliminating the need to remove the entire flange assembly or re-machine the flange body.
2Reliability
If the shroud coupling flange is completely removed and machined to form a new axially forward surface, then the seal element can seal against the rotating blade, but complex and precise machining is required to angle the axially forward surface to match changes in the upstream casing flange
Solution Approach 1:
The coupling flange is divided into the flange body and separate shim components. The shims are inserted into grooves on the flange surface, allowing the sealing function to be separated from the flange structure itself. This segmentation enables the shims to be replaced independently without removing the entire flange or fasteners.
Solution Approach 2:
The shims are designed as replaceable, relatively simple components compared to the expensive and complex flange assembly. When wear or deformation occurs, the inexpensive shims can be replaced rather than re-machining the entire flange, significantly reducing repair complexity and cost.
3Reliability
If a shim is positioned between the casing flange and the shroud flange to accommodate wear and/or deformation, then the seal element can seal against the rotating blade, but at least the shroud flange must be removed and any previously used shim must be removed, making it very time consuming and expensive
Solution Approach 1:
The coupling flange is divided into the flange body and separate shim components. The shims are inserted into grooves on the flange surface, allowing the sealing function to be separated from the flange structure itself. This segmentation enables the shims to be replaced independently without removing the entire flange or fasteners.
Solution Approach 2:
The grooves for receiving the shims are pre-formed on the flange surface during manufacturing. This preliminary preparation allows the shims to be quickly inserted and removed during maintenance without requiring complex disassembly procedures, significantly improving ease of repair.
4Reliability
If the shroud coupling flange is completely removed and machined to form a new axially forward surface, then the seal element can seal against the rotating blade, but if further deformation occurs later in time, the entire process must be repeated
Solution Approach 1:
The coupling flange is divided into the flange body and separate shim components. The shims are inserted into grooves on the flange surface, allowing the sealing function to be separated from the flange structure itself. This segmentation enables the shims to be replaced independently without removing the entire flange or fasteners.
Solution Approach 2:
The shims are designed as sacrificial components that can be discarded when worn or deformed and replaced with new ones. The expensive flange body is preserved and reused, while only the inexpensive shims are discarded and replaced, extending the overall service life of the coupling assembly.
Data Source
AI summary
A coupling flange for use in an industrial machine is disclosed. The coupling flange includes a body segment having an arcuate surface configured to couple to a surface of an adjacent body segment of an adjacent coupling flange. A first groove and a second groove are defined in the arcuate surface. A first shim is configured to be positioned in the first groove, and a second shim is configured to be positioned in the second groove. The first shim and the second shim are configured to mate the arcuate surface with the surface of the adjacent body segment of the adjacent coupling flange. One or both of the shims can be replaced with revised versions thereof to accommodate any wear or deformation in the coupling flanges without removing the flanges from the industrial machine.