Forward-Load Reduction Structures for Aft High-Pressure Compressor Stages
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Solution Overview
Problem
Gas turbine engines face challenges in minimizing thrust loads on high-pressure spool bearings, leading to component deterioration and reduced lifespan, while achieving higher efficiency, thrust, and reduced carbon emissions.
Innovation Solution
Redesigning the compressor portion with specific dimensional characteristics to reduce thrust loads on HP ball bearings, improve rotor life, and enhance load path stiffness, by optimizing the relationship between cavity height, vane height, and flowpath hub radius in aft stages, using innovative structural features such as bridge seals, box-type seal housings, and curvic couplings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the compressor section is designed with conventional components, then the engine can achieve basic compression function, but thrust loads on HP spool bearings increase leading to component deterioration and reduced lifespan
Solution Approach 1:
The patent applies parameter changes by optimizing the dimensional relationships between cavity height (Ch), vane height (Vh), and flowpath hub radius (Rh) in the aft-most compressor stage. By establishing specific ratio ranges (Ch/Vh between 0.95-5.1, Ch/Rh between 3.0-21.0), the design modifies geometric parameters to alter load distribution characteristics, thereby reducing thrust loads on HP spool bearings while maintaining compression functionality
Solution Approach 2:
The patent implements local quality by introducing a diverging load path specifically in the aft-most stage of the compressor. This localized structural modification creates a different load-bearing mechanism in this critical region compared to conventional uniform designs. The specific dimensional characteristics of the aft-most stage components are optimized to redirect and distribute loads locally, preventing excessive thrust from concentrating on the bearings
2Productivity
If the compressor section uses standard design, then manufacturing is straightforward, but efficiency and thrust performance are limited
Solution Approach 1:
The patent achieves improved efficiency by changing key geometric parameters of the compressor components. The optimized ratios of Ch/Vh and Ch/Rh in the aft-most stage improve airflow characteristics and compression efficiency. These parameter modifications enhance engine performance metrics including thrust and fuel efficiency without requiring fundamental redesign of the entire compressor system
Solution Approach 2:
The patent applies segmentation by focusing design optimization specifically on the aft-most stage of the compressor rather than redesigning all stages. This segmented approach allows targeted improvements in the critical rear section where load paths converge, while maintaining simpler designs in forward stages. The curvic coupling and seal housing configurations are also segmented into modular components for optimized performance
3Reliability
If the compressor section is designed with optimized load paths, then bearing loads are reduced, but structural complexity increases
Solution Approach 1:
The patent introduces intermediary structural elements such as curvic couplings and seal housings that act as mediators in the load transmission path. These components serve dual functions: they facilitate the diverging load path to protect bearings while also providing sealing and positioning functions. The curvic coupling between compressor stages and the seal housing around the rotor shaft are intermediary structures that distribute loads more favorably without requiring complete structural redesign
Solution Approach 2:
The patent applies multi-functionality by designing components like the seal housing and curvic coupling to perform multiple functions simultaneously. The seal housing not only provides sealing but also contributes to load distribution and structural support. The curvic coupling transmits torque while accommodating misalignment and contributing to the diverging load path. This multi-functionality reduces the need for additional dedicated components, limiting the increase in overall structural complexity
Data Source
AI summary
Structures for reducing forward loads in compressors are described. A compressor includes inner and outer circumferential support structures. The inner circumferential support structure includes an aft-most and forward spacer arms. The compressor also includes two stages, each including a vane having a root positioned at the outer circumferential support structure and a tip positioned radially inward from the root, and a rotor extending radially from the spacer arm adjacent to the vane. An intersection of the rotors and spacer arms defines centrally located points. An arrangement of a first line extending through the points forms an angle with a second line parallel to a longitudinal centerline and extending through the tips of the vanes. The angle is greater than 0° and less than or equal to 45°.