Coupling Flange Shim Grooves for In-Place Wear Repair
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Solution Overview
Problem
Existing methods for repairing worn or deformed coupling flanges in industrial machines, such as turbomachines, are time-consuming and expensive, requiring complete removal and machining of the flanges or the use of radially extending shims, which are also costly and inefficient.
Innovation Solution
A coupling flange design featuring grooves and shims that allow for the independent adjustment and replacement of shims without removing the flanges, enabling precise alignment and sealing without extensive machining, using radially and axially spaced grooves and shims to accommodate wear and deformation.
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 process becomes very time consuming and expensive
Solution Approach 1:
The coupling flange is divided into the flange body and separate shim components. The shims can be independently removed, replaced, or adjusted without removing the entire flange assembly, enabling quick repair while maintaining sealing performance.
Solution Approach 2:
Shims are introduced as intermediary components between the coupling flange and the mating surface. These shims compensate for wear and deformation, allowing the seal element to maintain proper sealing without machining the flange itself.
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 the repair cost increases significantly
Solution Approach 1:
The shims are designed as inexpensive, replaceable components that can be worn or deformed and then simply replaced. This avoids the high cost of machining operations and extends the service life of the expensive flange assembly.
Solution Approach 2:
Shims serve as sacrificial intermediary components that protect the expensive coupling flange from wear. Instead of machining the flange, the shims are replaced, significantly reducing repair costs.
3Reliability
If a shim is positioned between the casing flange and the shroud flange to accommodate wear and deformation, then the seal element can seal against the rotating blade, but the shroud flange must be removed which is very time consuming
Solution Approach 1:
The sealing interface is segmented into multiple components: the flange body, the shim, and the seal element. This allows the shim to be accessed and replaced independently through the groove without removing the flange assembly.
Solution Approach 2:
The shim is extracted as a separate, removable component that can be accessed through a groove in the flange. This extraction allows replacement of the shim while leaving the flange installed, eliminating the time-consuming flange removal step.
4Reliability
If conventional repair methods are used for coupling flanges, then wear and deformation can be addressed, but complex and precise machining is required to angle the axially forward surface
Solution Approach 1:
The shim acts as an intermediary that provides the necessary angular adjustment and alignment between flanges. Instead of complex machining to create angled surfaces, the shim's geometry provides the required alignment, significantly simplifying the repair process.
Solution Approach 2:
The shim allows for easy adjustment of geometric parameters such as angle and position. By changing the shim's dimensions or orientation, proper flange alignment can be achieved without complex machining operations.
Data Source
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AI summary
A coupling flange (200) for use in an industrial machine (100) is disclosed. The coupling flange (200) includes a body segment (202) having an arcuate surface (204) configured to couple to a surface (206) of an adjacent body segment (208) of an adjacent coupling flange (210). A first groove (220) and a second groove (222) are defined in the arcuate surface (204). A first shim (230) is configured to be positioned in the first groove (220), and a second shim (232) is configured to be positioned in the second groove (222). The first shim (230) and the second shim (232) are configured to mate the arcuate surface (204) with the surface (206) of the adjacent body segment (208) of the adjacent coupling flange (210). One or both of the shims (230, 232) can be replaced with revised versions thereof to accommodate any wear or deformation in the coupling flanges (200, 210) without removing the flanges (200, 210) from the industrial machine (100).