Flexible Induction Heating Jacket for Turbine Hub Disassembly
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Solution Overview
Problem
Traditional methods for assembling and disassembling components in gas turbine engines, such as hubs and shafts, are time-consuming and often result in damage due to uneven heating and cooling, leading to increased costs and maintenance challenges.
Innovation Solution
A flexible induction heating jacket is used to wrap around the hub, with selectively separable electrical connectors, allowing for controlled differential heating between the hub and shaft by regulating power through a controller based on temperature sensors, ensuring uniform expansion for efficient assembly or disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional assembly and disassembly methods are used for turbine engine components, then the process is simple and requires minimal equipment, but the operation is time-consuming and may result in component damage
Solution Approach 1:
The patent applies thermal expansion parameters by heating the hub to a controlled temperature range (150-300°C) to increase its internal diameter, allowing the shaft to be easily inserted or removed. This parameter change enables rapid assembly/disassembly without mechanical force that could damage components
Solution Approach 2:
The hub is selectively heated using an induction heating apparatus, causing thermal expansion of the hub material. This expansion increases the clearance between the hub bore and shaft, facilitating smooth assembly or disassembly operations while preventing component damage
2Temperature
If uniform heating is applied to both hub and shaft, then the heating process is simple, but differential temperature between components is insufficient for effective assembly or disassembly
Solution Approach 1:
The heating system applies heat locally and selectively to the hub only, using induction heating coils positioned to contact or near the hub surface. The shaft remains unheated or minimally heated, creating the necessary differential temperature condition for assembly/disassembly
Solution Approach 2:
Temperature sensors monitor the hub temperature in real-time, and this feedback is used by the controller to regulate power delivery to the induction heating coils. This closed-loop control maintains the hub at the optimal temperature range while preventing overheating and ensuring sufficient temperature differential
3Manufacturing precision
If conventional heating methods are used, then equipment is simple, but heating uniformity is poor leading to component damage
Solution Approach 1:
The patent replaces conventional mechanical or flame-based heating methods with induction heating technology. This electromagnetic heating method provides uniform, controlled heat distribution through the hub material, eliminating hot spots and uneven heating that could cause component distortion or damage
Solution Approach 2:
The induction heating system precisely controls heating parameters including power level, heating duration, and temperature distribution. This controlled parameter management ensures uniform heating across the hub surface and internal structure, preventing thermal stress and component damage
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 method reduces assembly and disassembly time, eliminates the need for liquid nitrogen, and minimizes component damage, thereby saving costs and ensuring smooth operation without scrap or repair.
Implementation Method 1
an oscillating magnetic field is generated by the induction heating apparatus
Implementation Method 2
induces eddy currents in the hub
Implementation Method 3
The heated hub expands; this facilitates assembly or disassembly of the mating hub and shaft
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A first component, such as a hub (10) of a gas turbine engine (2) is assembled or disassembled from a second component, such as a shaft (12) by induction heating, using a flexible heating jacket (40) that is wrapped about an outer circumferential surface (18) of the hub. The jacket (40) includes an electrically conductive, flexible cable (42), having a plurality of loops (44). The jacket is selectively opened and closed with a plurality of electrical connectors (54) coupled to each respective loop of the cable. A power source (64) passes current through the respective cable loops, which heats the hub. The induction heating is applied to the mating components in the engine, in order to create a sufficient temperature differential that permits assembly or disassembly of the hub and shaft. A controller (30) regulates power applied to the hub and shaft and monitors their temperature with temperature sensors (15,16).